Dehumidification and heating
for energy-efficient spray drying
Uncontrolled climate fluctuations make spray drying unpredictable
Spray drying is a critical process widely employed in food, pharmaceutical and other industrial production processes to achieve precise product specifications and maintain batch-to-batch consistency. Airborne moisture, seasonal fluctuations and uncontrolled ambient humidity can trigger operational risks and quality deviations, significantly impacting performance and reliability.
High moisture content in the intake air increases the risk of powder sticking to spray dryer walls, causing particle agglomeration, equipment fouling and reduced throughput with inconsistent bulk density and high rejects. Excess humidity also promotes microbial contamination - mold, fungi, and bacteria - compromising product safety and regulatory compliance. Condensation on surfaces can lead to powder clumping, equipment blockages, corrosion, and unplanned downtime with costly maintenance interventions, while in direct-fired systems, dust particles exposed to ignition sources can create explosion hazards.
Because spray drying is inherently energy-intensive, any inefficiency in air handling treatment further amplifies energy consumption and operating costs. Consequently, manufacturers face variability in product quality, frequent cleaning cycles, and elevated energy expenditure, particularly under adverse climatic conditions. These factors collectively diminish overall process reliability and productivity.
Without climate control, you risk:
- Unpredictable product volume yields with inconsistent bulk density and substantial rejects
- Equipment fouling, powder clumping, and unplanned downtime with major maintenance costs
- High energy consumption and operating costs significantly impacting the carbon footprint
- Microbial contamination compromising product safety and regulatory compliance
Our precision-engineered air treatment solutions ensure seamless and predictable spray drying process, regardless of weather conditions, to further maximize throughput and enhance product quality while reducing energy consumption and CO2 emissions.
Marcel van den Berghe, Head of Spray Drying Centre of Excellence
Munters
The critical need for climate control in spray drying
Without proper climate control, a spray drying line cannot run at peak performance year-round, impacting product quality and profitability.
Controlling air humidity and temperature is essential for stable, optimized drying conditions in any season. This ensures consistent output, improved energy efficiency, and greater process reliability.
An integrated approach combining desiccant dehumidification, high-efficiency indirect air heating, and heat recovery technology ensures consistent, round-the-clock operation regardless of season or climate.
Effects of precision-engineered air treatment:
- Consistent year-round reliability with maximized throughput and predictable product volume yields
- Stable drying conditions minimizing weather-related disruptions and preventing powder lumping and equipment fouling
- Energy efficiency significantly lowering fuel costs and CO₂ emissions for each ton of powder produced
- Reduced CIP cleaning cycles and compliance with strict hygienic and sanitary standards
Superior product quality
Munters' air treatment solutions create a controlled, low-humidity environment that prevents powder from lumping, clumping, or spoiling during spray drying. This ensures powders maintain the intended moisture content and particle characteristics, delivering uniform bulk density and minimal rejects.
By eliminating risks of scorch from overheating and spoilage from excess moisture, our systems safeguard product integrity and compliance with strict sanitary standards.
Consistently dry, clean air improves shelf life, reduces contamination risks, and shortens CIP cycles, resulting in uniform higher-quality products and greater process reliability.
Benefits of indirect heating
Indirect-fired recirculating gas heaters provide clean, contaminant-free process air by isolating combustion gases, eliminating hazardous by-products such as nitrites and nitrates. This design minimizes dust ignition risks, supports FSMA compliance, and meets stringent food safety and GMP standards.
Operating at up to 98% efficiency, these heaters deliver stable thermal performance for energy-efficient spray drying while reducing emissions and fuel consumption. The result is a safer, more sustainable process that protects product quality, lowers operating costs, and ensures reliable performance under all conditions.
Customers using Munters' solutions for spray drying applications
A leading infant formula manufacturer in the Netherlands partnered with Munters to implement a comprehensive air treatment solution tailored for high-demand spray drying operations.
An integrated system combining PureSystem, VariMax IFRG, PureHP, PureSound, PureRecup, and a heat pump ensured precise control of air humidity and temperature under varying seasonal conditions. The approach also incorporated heat recovery and energy optimization technologies to minimize fuel usage and environmental impact.
By implementing Munters’ air treatment solutions, the customer achieved year-round reliability, improved sustainability, and a fast return on investment—all while safeguarding the quality and safety of infant formula products.
Based in Zwolle, the Netherlands, Sensus uses the chicory root to produce inulin, a sweetener used in the food industry, utilizing a spray drying process to convert the concentrated inulin solution to powder.
One of the most important parameters in the spray drying process is climate fluctuations and temperature and moisture content determine the product’s glutinosity, which can cause production stops due to fouling.
The Munters PureSystem Premium Plus 3500 with the patented HPQ Quantum desiccant rotor optimizes Sensus spray drying process with perfect inulin moisture content.
With our proven technology, climate is no longer a variable but a constant factor, and production capacity has increased by 40%.
Dehumidifiers and heaters for spray drying applications
Industries where spray drying is a critical application
Spray drying in food production faces humidity-driven challenges like powder lumping, clogging, and microbial risks in products such as infant formula, cheese, coffee, dairy, and whey protein.
Seasonal fluctuations often force slower feed rates, reducing throughput and raising energy costs. Munters’ integrated approach, combining desiccant dehumidifiers with high-efficiency indirect air heaters and heat recovery delivers stable conditions year-round.
This solution boosts capacity by up to 40%, cuts energy use by up to 40%, and ensures superior powder quality with minimal fouling. Reduced CIP cycles, lower CO₂ emissions, and fast ROI make it a sustainable, high-performance choice for food manufacturers.
The pharmaceutical industry demands precise control to maintain powder integrity for lactose, maltodextrin, proteins, and infant formula in the spray drying process.
High ambient moisture can cause fouling and frequent downtimes, leading to inconsistent particle size, and contamination risks and impacting compliance and efficiency.
Munters’ integrated approach, combining desiccant dehumidifiers with high-efficiency indirect air heaters and heat recovery creates predictable drying conditions regardless of climate.
Benefits include up to 40% higher throughput, 15-40% energy savings, and superior product uniformity. Hygienic stainless-steel design meets GMP standards, while reduced cleaning downtime and lower emissions support sustainability. With rapid ROI, this system ensures reliable, cost-effective pharmaceutical production.
Spray drying for chemicals and fertilizers, such as battery-grade powders and detergents, faces challenges from moisture-induced clumping, corrosion, and equipment blockages, leading to costly downtime.
Munters’ integrated approach, combining desiccant dehumidifiers with high-efficiency indirect air heaters and heat recovery creates predictable drying conditions regardless of climate ensures consistent performance in any climate.
Operators achieve up to 40% increased capacity, significant fuel savings, and reduced maintenance thanks to minimized fouling. With superior thermal efficiency, lower CO₂ emissions, and fast ROI, Munters ensures sustainable, reliable production for chemical and fertilizer manufacturers.
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