Spray Congealing

Spray Congealing (SC), Chilling or Cooling is an atomization process in which a molten material is sprayed into a cooled chamber, solidifying into spherical particles. This technique enables solvent-free encapsulation, preserving properties and ensuring stability and easy handling. It consists of a compressed air and sample heating system (SC-A) and an air cooling system (SC-R), which can be used for low-melting-point samples.

The process air is cooled and controlled in the SC-R before entering the atomization chamber, creating the conditions required for rapid solidification of the sprayed droplets. This cooling ensures the formation of solid particles while preserving the characteristics of the encapsulated material.

The sample is heated in the SC-A to its molten state and kept under thermal control, ensuring fluidity and uniformity during atomization. The compressed air, also heated, assists in efficient spraying, allowing the formation of homogeneous droplets for subsequent solidification in the cooled environment.

The air cooling system (SC-R) can be used for low-melting-point samples. This module consists of:

• Refrigeration and dehumidification unit;

• PT-100 temperature sensor;

• Insulated tubing for connection to the air inlet of the Labmaq do Brasil spray dryer;

• Touchscreen HMI module for temperature adjustment, allowing control in the 0 to 25 °C range.

The heating system (SC-A) allows precise and independent control of compressed air and sample temperatures to be atomized for particle formation through spray congealing.

This module consists of:

• Support structure suitable for heating the sample to be atomized;

• Electric resistance heating with safety sensor for compressed air detection to prevent damage in case of airflow interruption;

• Adjustment of molten sample flow;

• PT-100 temperature sensor;

• Heating module for temperature adjustment (25 to 180 °C), PID controlled.