Spray Drying & Agglomeration

GEA Niro specializes in industrial spray drying and agglomeration, and has long been the world leader in spray drying technology. We have supplied the most industrial drying plants in operation today. All systems comply with sanitary standards and are capable of being cleaned in place.

The spray dryers below are the most commonly used in the food and dairy industry.

A spray dryer layout featuring either a rotary atomizer or spray nozzle atomizer.

Conventional Two-Stage Spray Dryer

Powder discharged from the drying chamber can be further dried and cooled in a vibrating fluid bed, the GEA Niro Vibro-Fluidizer®. This two-stage drying concept achieves better overall heat economy and is suitable for many food and dairy products. When non-agglomerated powders of non-fat products are dried, a pneumatic transport system can replace the fluid bed.

A space saving spray dryer with integrated fluid bed

Compact Spray Dryer

Atomization is created by either a rotary atomizer or spray nozzle atomizer. The location of the fluid bed within the drying chamber permits drying to be achieved at lower temperature levels resulting in higher thermal efficiencies and cooler conditions for powder handling. The plant can be equipped with pneumatic transport system for many powders or with an external vibrating fluid bed for agglomerated powders.

GEA Niro COMPACT DRYER™ with integrated Fluid Bed Dryer

Microphoto: spray dried skimmed milk powder

Flash animation of a COMPACT DRYER™

GEA Niro Fluidized Spray Dryer - FSD™ (Food and Chemical)

GEA Niro Fluidized Spray Dryer — FSD™

The Fluidized Spray Dryer (FSD™) combines spray drying and fluid bed drying technologies and offer excellent product flexibility and excellent thermal efficiency.

Pressure nozzles or a rotary atomizer spray the feed down towards the fluid bed where agglomeration incorporating finer, recycled material takes place. Exhaust air outlet is let through the roof causing further agglomeration in the spray zone.

Sticky products can be dried successfully, and the concept is ideal for drying heat sensitive products, and improved aroma retention is accomplished.

Product: Agglomerated (instant), free-flowing dustless powders. Agglomerated powders are obtained in systems based upon the integrated fluid bed or belt and a multi-stage concept where moist powder, produced during the first drying stage, forms agglomerates, which are after-dried and cooled in the following stages.

GEA Niro Fluidized Spray Dryer (FSD™)

Microphoto: Dye

Flash animation of Fluidized Spray Dryer (FSD™)

GEA Niro Multi-Stage Dryer — MSD™

GEA Niro Multi-Stage Dryer - MSD™ (Dairy)

The spray is created by a spray nozzle atomizer. Operational flexibility enables production of a wide range of physical properties. The process produces non-dusty, free flowing agglomerated powders with high flavor retention. It operates with low outlet-temperatures, achieving high thermal efficiency. Dry ingredients for additional flavor or nutrient fortification can be added within the system to further promote capabilities and improve formulation efficiencies. This design concept is successful for drying high fats, hygroscopic, and sticky products that are difficult to handle in more conventional designs.

GEA Niro Integrated Filter Dryer (IFD™)

GEA Niro Integrated Filter Dryer (IFD™)

IFD™ Integrated Filter Dryer - Combines an integrated fluid bed and filter arrangement. It is a adaptable and flexible spray dryer for the food ingredients, food, dairy, chemical, and pharmaceutical industries.

The Integrated Filter Dryer (IFD™) features and benefits:

• Improves powder quality
• Total in-place recovery of powder
• Features integrated fluid bed
• Simplifies CIP operations
• No handling of product outside drying chamber
• Compact plant layout
• Reduced noise level
• Lower energy consumption

A tower spray dryer with a top mounted nozzle assembly featuring a fines return capability.

GEA Niro TALL FORM DRYER™ – TFD™ (a.k.a. nozzle tower spray dryer)

The atomized droplets dry while gently falling down the tower. Further drying and cooling are carried out in a vibrating fluid bed located under the tower. The TALL FORM DRYER™ is suited for both non-fat and fat-containing products, producing non-agglomerated and agglomerated free-flowing powders.

GEA Niro FILTERMAT® Spray Dryer

GEA Niro FILTERMAT® Spray Dryer FMD

The FILTERMAT® Spray Dryer is frequently used in food and dairy applications. It operates at a low oulet temperature, achieving high thermal efficiency. It is the recommended system for drying high fat, sugar-based, hydrolyzed, and fermented products.

GEA Niro FILTERMAT® Specifications

Flash animation of GEA Niro FILTERMAT® Spray Dryer