News > Avoid Losses in the Drying Process – 5 Common Mistakes When Using a Spray Dryer

Spray drying is a widely used technique for transforming liquids into powders with high efficiency and control. However, process failures can lead to product loss, poor final quality, or even production downtime.

Here are 5 common mistakes and how to avoid them to ensure a more stable, productive process with excellent yield.

✅ 1. Total solids outside the ideal range

Common mistake: using concentrations that are too low or too high.
Problem: low concentrations result in poor yield and high cyclone losses; high concentrations can hinder feeding or compromise atomization.
Solution: keep total solids within the recommended range for your system.

✅ 2. Improper inlet temperature adjustment

Common mistake: using a standard temperature without considering product sensitivity.
Problem: high temperatures degrade sensitive compounds; low temperatures cause incomplete drying.
Solution: adjust the inlet temperature according to the thermal stability of the material. Ingredients like flavors, enzymes, natural extracts, etc., require finer control.

✅ 3. Feed rate incompatible with system capacity

Common mistake: pumping the solution too fast to increase productivity.
Problem: hot air can't dry the entire solution in time → resulting in wet powder or even sludge inside the chamber.
Solution: increase the feed rate gradually while monitoring powder behavior in the cyclone, outlet temperature, and buildup in the system. Fine-tuning is key.

✅ 4. Misalignment of nozzle or atomizing disk

Common mistake: incorrect assembly or worn-out components.
Problem: uneven atomization → poorly formed particles, clogging, and wall buildup.
Solution: perform frequent visual inspections and ensure proper assembly after each cleaning. Carry out preventive maintenance regularly.

✅ 5. Inadequate cleaning and maintenance

Common mistake: underestimating residue buildup or using aggressive cleaning methods.
Problem: cross-contamination, process inconsistencies, and mechanical failures.
Solution: implement a validated cleaning protocol with regular inspections. Prefer full disassembly with part-by-part cleaning using appropriate brushes and compatible products.

✅ BONUS: Use data to your advantage

Modern equipment like Labmaq’s allows real-time recording of temperatures and flow rates. Use this data to build a process history and detect deviations before they become losses.

Small details make a big difference in the spray drying process. Knowing the most common mistakes and their solutions is essential to ensure product quality, higher yield, and reduced downtime.

Facing challenges in your drying process? Talk to the Labmaq team — we can help you optimize your process, whether in the lab or at industrial scale.

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