Pigments

With deep process expertise, Advanced CFD simulation and highest manufacturing quality SAKA offers most advanced Spray Drying technology available in the market.

TOTAL CONTROL OVER DRYING PROCESS

SAKA’s Spray Dryers are designed to serve your specific process needs to deliver best output efficiency, with optimum operational costs and no product wastage.

The Spray dryers are designed based on inputs derived from in-depth analysis of your process parameters, available space, and the application. Engineering and automation in SAKA’s Spray Dryers provide you with complete control on configuring key process characteristics such as moisture content, particle size, bulk density, flow patterns etc. to manufacture the desired product.

With an installed base of over hundred Spray Dryers,

delivered in just seven years, SAKA is also credited with successful installation of one of the biggest Spray Drying plant in India at Bhavnagar, Gujarat.

SAKA employs highly advanced methodology of Computational Fluid Dynamics (CFD) analysis, to deliver guaranteed results for your Business, Process reliability and system performance. CFD simulation helps to foresee performance before actual execution of the systems, without actual installation of the system. It also helps understand the most vital parameters for improving performance.

TYPES OF SPRAY DRYER

CO-CURRENT SPRAY DRYER

Rapid drying with higher thermal efficiency

In this type of Dryers, air and feed are introduced from opposite directions. Feed is introduced from the top and hot air is introduced from the bottom. Counter Current Dryers have better efficiency and output but are not ideal for heat sensitive material. Typically, these types of Dryers are ideal for products like Soaps, Dyestuff, Detergents etc.

Here feed first comes in contact of warm at its lowest temperature and gradually gets exposed to the hotter air. Counter Current Dryers are more effective and have better thermal efficiency then that of a Co-current Spray Dryer.

MIXED FLOW SPRAY DRYER

Superior performance with better mixing process

This is a combination type of air flow system i.e. Counter as well as Co-current. Here Air is introduced from the top and atomizer is located at the bottom, thus providing mixed flow effect. This type of drying is slightly identical to counter current hence it is not applicable for heat sensitive material.

SPRAY DRYER WITH NOZZLE OPERATION

Uniform particle formation with effective drying

In case of Spray Dryer with Nozzle, Dryer comes with a spray nozzle which facilitates formation of fine droplets at very high speed. These kinds of Dryers are used where faster evaporation of heat is required.

Here feed is introduced in drying chamber through a high-pressure nozzle forming small droplets. These fine droplets get dried immediately as soon as they come in contact of hot air.

SPRAY DRYER WITH ROTARY ATOMIZER

Instant drying with high-speed dispersion

Spray dryers with Rotary Disc Atomizers from SAKA are capable to handle material in large quantities and any viscosity. Wheel design is customized according to powder characteristics. Ideal for applications like herbal extracts, ceramics, inorganic chemicals, and dye stuffs. these Spray Dryers are used where liquid feed is required to converted into fine droplets.

Feed is introduced through a high-speed rotating disc which throws liquid outward at very high velocity. This leads formation of fine droplets which are dispersed on the walls of the spray dryer. these droplets when comes in the of hot air/gas to form dry solids, granulate or agglomerate particles.

ADVANCED DRYING SYSTEM

Achieve the best efficiency with advanced drying system.

Apart from Single Stage Spray Drying, SAKA also provides advanced double stage and multistage drying solutions.

Double stage drying a combination of Spray Dryer and Fluid Bed or Vibrating Bed Dryer. Here moisture content after spray drying is relative higher as compared to single stage. After spray drying moisture content is further reduced in second stage where it passes through Fluid Bed Dryer or Vibrating Bed Dryer. Double stage drying enables drying at lower temperature making it suitable for heat sensitive materials and avoids its degradation.

A compact laboratory spray dryer with a maximum temperature of 260oC and liquid flow rate of up to 1000ml per hour. This unit is ideal for research and development and sample preparation of many products. All units feature a simple and intuitive touch screen operation system with recipe functions and USB data logger.

Reproducible powder production at lab scale; Ideal for scale up to pilot or production; Proven performance – the most established & flexible instrument for LAB spray drying; Cost efficient – achieve reproducible result at minimal costs; Easy to use; Simple switching between two nozzle variants; High yields (up to 70%); Shorter times to optimize formulation.

A compact laboratory spray dryer with a maximum temperature of 260oc and liquid flow rate of up to 1000 ml per hour. This unit is ideal for research and development and sample preparation of many products. All units feature a simple and intuitive touch screen operation system with recipe functions and USB data logger.

Capacity: 1 – 2 kg / hr water evaporation

Used for spray drying, encapsulation and others; Designed for solvent and aqueous feeds; Visible process due to glass assembly; Easy to handle glassware. High performance cyclone; High yields; Self-contained and supplied complete and ready for immediate operation; Compact design and easy to move around; Fast drying process (up to 2 kg/hr); Shorter times to optimize formulations.

Reproducible powder production at lab scale; Ideal for scale up to pilot or production; All units feature a simple and intuitive touch screen operation system with recipe functions and USB data logger.

Consistent atomization.

One of the reasons for the reproducibility of the Lab 1 Glass Laboratory Spray Dryer is the durable and precise nozzle technology. The nozzle comes with a de blocker needle which can be pushed through the nozzle in case of clogging. The de blocker frequency is user selectable. Optional, nozzle cooling is available. The nozzle can be cooled with regular tap water. Spraying of heat sensitive product is possible.

Touch screen PLC operating system.

The touch panel PLC operating system allows the user to control all the system parameters with the touch of a finger. The blower, air heater and feed liquid pump are operated from this panel. The system parameters such as inlet hot air temperature, outlet exhaust air temperature, feed and blower frequency are set by touching the corresponding displayed value and entering the new value in the set screen that appears.

A data trend screen shows a record of the air temperatures, heater output and feed liquid pump output during the experiment. The user can visually see the temperature record and quickly understand it. For data analysis, a daily report screen and experiment data can be viewed with option to save to an USB flash drive for use in a PC computer.

Access to only two sides

Access to only two sides of the spray dryer is required for normal operation. The touch panel and product collection pot are located so that all operations are performed from one operating point.

Additional Features:

• Online nozzle cleaning with deblocker.
• 3-Fluid nozzle for spray immiscible fluids.
• Inert loop for condensation of solvents and feedback of inert gases.
• Integrated magnetic stirrer and hot plate.
• Fast setup and cleaning times.
• Lowest maintenance costs
• Requires only AC 220/240v 50/60Hz power supply (other power requirements available)

Fully automated PLC based touch screen operator panel with recipe function and USB data logger. Safe, flexible and easy to handle.

• Capacity: 3-5kg/hr water evaporation.
• SS 316L construction.
• High purity design.
• Ideal for low volumes.
• Various pharmaceutical grade finishes.
• Sanitary type ports are standard.
• Solvent and aqueous feeds.
• HEPA filters for gas streams.
• Pressure and two nozzle systems.
• Co-Current spray.
• High yields.
• Compact design ideal for laboratories and kilo labs.

Recent Customers

• 3M Corp. USA (2 units)
• Misr Café Co., Egypt
• Taste Master Flavors, India
• Lupin Ltd., India
• Praj-Matrix, India
• Givaudan, India
• ITG, Israel
• Vedent Dyestuffs Intermediates Pvt. Ltd., India

UNIFORM AND EFFECTIVE DRYING

Rotary Dryers are one of the widely used Dryer in process industry. Especially in fertilizer and minerals industry for drying products such as coal, clay, gypsum, kaolin, limestone, mineral sand, potash, silica sand etc.

Rotary Dryers from SAKA provide controlled, uniform, and efficient drying to help you achieve desired product quality. With a specialized design and sturdy construction our Rotary dryers can provide excellent thermal efficiency.

Rotary Dryers consist of cylindrical shell supported by riding rings to provide circular motion. These dryers come with lifter or flights on its inner circumference to lift and distribute material. This lifter also facilitates material movement towards final discharge point. Rotary dryers are always aligned on slight slope to facilitate movement of material from feeding point to discharge point under gravity.

Our stringent quality standards and detailed CFD analysis ensures a consistent and enduring performance.

SAKA employs highly advanced methodology of Computational Fluid Dynamics (CFD) analysis, to deliver guaranteed results for your Business, Process reliability and system performance. CFD simulation helps to foresee performance before actual execution of the systems, without actual installation of the system. It also helps understand the most vital parameters for improving performance.

TYPES OF ROTARY DRYER

CO-CURRENT ROTARY DRYER

Total control over moisture content.

The Co-current type of Rotary Dryer is ideal for the materials that has tendency to stick and has high moisture content. Here Air and feed are introduced from the same direction and material comes in contact of hot air at its highest temperature, which instantly evaporates surface moisture.

The initial heat transfer rate is high, causing an immediate and considerable drop in gas temperature, which prevents overheating of the material and the dryer shell. The material which is in its final stage comes in contact of air/gas at its lowest temperature thus enabling the easy control over the moisture.

COUNTER CURRENT ROTARY DRYER

Providing best energy efficiency consistently. Counter current type of rotary dryer is an ideal solution for materials that must be dried to contain very low level of moisture. Here warm air is introduced at the discharge point of the Dryer.

The material meets the warm air first at its lowest temperature, which goes on increasing as the material travels further.

The material which is at its final stage comes in contact of air/gas at its highest temperature thus maintaining very low level of moisture content.

DIRECTLY FIRED CALCINER

Effective drying for high temperature processing.

Directly Fired Calciners are used for high temperature application. The process usually has longer resistance time, The length of diameter ration is often more than 10:1 to control the temperature along the length of the Calciner. Burner fires directly from the discharge end of the dryer.

The drying is achieved in three ways – by radiation from the burner flame, conduction from the refractory lining and convection by contact with the hot gases.

IN-DIRECTLY FIRED CALCINER

Efficient drying for low temperature processing.

In Indirectly Fired Calciner, material is heated with the help of the burners which are on the outer periphery of the dryer. Here, the heat is transferred by way of radiation and conduction through the cylinder wall.

The rotary drum is partially enclosed and externally heated by a series of burners mounted in an insulated stationary chamber or jacket. Ideal for materials which require medium or low temperature, Indirectly Fired Calciners are used for drying dusty, fine or heat sensitive materials.

TUBE BUNDLE DRYER

Controlled drying performed efficiently.

Tube Bundle Dryers provide effective and efficient drying for materials which require lower drying temperatures. Main element of these type of Dryers are steam heated tube, it dries the product by rotating inside a firm housing. SAKA’s Tube Bundle Dryers are highly efficient and require less warm air to dry the product thus there is less emission of air.

In Tube Bundle Dryers, feed comes in contact of heated tube and not directly heating medium. This makes is perfectly applicable for products which are free flowing and non-sticky. Typically, these Dryers are indirect type Dryer with counter current flow principle i.e. warm air flow in opposite direction of the feed.

CONDUCTION DRYER

High quality product output, guaranteed.

Conduction Dryers from SAKA are highly energy efficient. Ideal in case of heat sensitive material, Conduction Dryers offer controlled drying process atmosphere to ensure quality final product output.

Conduction dryer transfers the heat by contact of two surfaces the metal wall and heat jacketed vessel with agitator. Using electricity as source of energy, jackets are heated up, which transfers the heat to the drying surface leading to controlled drying of feed.

The Conduction Dryer comes with unique feature of sectional starting, which means you can heat up specific section of the Dryer giving very high-quality product output, zero degradation of the product and excellent energy efficiency.