Industrial Dryers

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

Our Food Freeze Drying Machines come in various capacities, including a 30 kg/day model (R-01) with automatic features, cast iron construction, and a three-phase electric power system. For larger-scale operations, our REVA brand offers a 300 kg/day capacity freeze dryer (R-02), crafted from stainless steel for durability and efficiency.

Need even more capacity? Our 500 kg/day Food Freeze Dryer (R-10) is ideal for industrial use, boasting automatic operation, three-phase power, and the renowned reliability of the REVA brand.

For pilot-scale and laboratory applications, we provide options like the 2 kg Pilot Food Freeze Dryer (R-08), offering precise temperature control, compact design, and efficient water removal capacity.

Our commercial-grade freeze dryers are engineered for high-volume processing, such as the Commercial Food Freeze Dryer (R-11), capable of handling up to 150 kg of material per day with advanced features like steam defrosting and a large effective drying area.

In addition, we offer Vacuum Food Freeze Dryers for specialized needs, including a 1000 kg/day capacity model (R-16) with automatic operation and stainless-steel construction.

For pharmaceutical-grade applications, our Compact Pharma Grade Freeze Dryer (R-12) ensures consistent performance with features like automatic mode, powder-coated surface treatment, and a production capacity of 20 litres per hour.

Our Laboratory Freeze Dryers (R-14) provide precise temperature control, steam defrosting, and a sizable effective capacity of 200 litres, making them ideal for research and development purposes.

Lastly, our Food Preserving Dryers offer a capacity of 60 kg processing capacity, single-phase power, and automatic operation, ensuring efficient preservation of food products.

At HygiFix, we prioritize quality, reliability, and customer satisfaction. Explore our range of freeze dryers tailored to meet your specific requirements, backed by our commitment to excellence in manufacturing, exporting, and supplying premium freeze-drying solutions.

We deal in high quality of products which are available on customer demand at best prices. We are the leading manufacturers, exporters, and supplier of an impeccable array of Food Freeze Dryer, Lyophilizer Machines & Food Preserving Dryers.

SAKA make Fluid Bed Dryers are ideal for agglomeration, granulation, or dry powder formation. Fully customized to meet your specific requirement and trusted by many companies in India and abroad.

CONTROLLED DRYING AND MOISTURE REMOVAL FOR YOUR FEED.

SAKA’s Fluid Bed Dryers (FBD)are specially designed to suit wide range of materials, particle sizes and properties. In a short span of time SAKA has successfully designed and installed a full range of Fluid Bed Dryers, with output from a few hundred kgs per hour to 100 Tonnes Per Day.

Fluid Bed Dryer (FBD) works in continuous or batch type processing. FBD comes with a perforated bed at the bottom. Hot air is blown through this perforated bed causing material to flow in air stream. Hot air is supported with sufficient velocity which causes material to stay in fluidisation state. This causes material to dry while it is in the flow.
Agglomeration

In special cases of Fluid Bed Spray granulation, particulates are built up by spraying liquid on the granules which are in fluidisation state. Particles which are ideal for FBD are pre-processed in steps such as crystallization, coagulation, or polymerization. In some cases, dry and wet particles are formed by spray drying prior entering FBD.

SAKA employs highly advanced method 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.

VIBRATORY FLUID BED DRYER

Controlled drying with continuous processing

Vibratory Fluid Bed Dryer are used for mass heat transfer and have relative smaller residence time. SAKA’s Vibratory Fluid Bed Dryers are known for its versatile applicability with an ability to process wet as well as semi wet products.

Vibratory motion in this type FBD’s moves the product through Dryer. Usually a push-pull system is used to balance the pressure to slightly negative in the free board of the fluid bed. Depending upon the product and available heat source, direct or indirect heating may be applied. Then the exhaust air is cleaned by bag filter, cyclone with or without wet scrubber.

SAKA’s Vibratory Fluid Bed Dryer are known for maintaining equilibrium of thermal efficiency and moisture content of the material thus ensuring effective, efficient, and controlled drying.

h4>ADVANCED DRYING SYSTEM

Achieve the best efficiency with advanced drying system.

Apart from Fluid Bed Dryer and Continuous Fluid Bed Dryer, SAKA also provides advanced double stage and multistage drying solutions.

Double stage drying is 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.

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.

Flash Dryers are known for their economy and quick drying capacity, SAKA make flash dryers cater to a wide range of materials including those that are heat sensitive, explosive, and reactive in nature.

QUICK AND EFFICIENT MOISTURE REMOVAL

Flash Dryers are ideal for processing wide range of materials like powders, cakes, granules, flakes, pastes, gels, and slurries.

SAKA’s Flash Dryers are known for their simple construction and excellent product quality. Shorter residence time of these type of dryers makes efficient feed dispersion an important and critical aspect of the process. SAKA’s team of experts and engineers always ensure that you get the proper and effective dispersion of your feed.

The drying process is carried out by exposing wet material to hot air travelling at very high velocity. the feed is dispersed into a stream of hot air which pneumatically conveys the material in the drying chamber, feed dries instantly as it is conveyed. Further, material is passed through a cyclone and scrubbers or bag filters to get the final output. Scrubbers and bag filters ensure that exhaust air is clean and meets the environmental norms. Option of recycling complete or partial exhaust air / gas can be provided depending upon the feed properties and type of material.

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 FLASH DRYE

FLASH DRYER

Faster, better, and economical drying

Flash Dryers are one of most economical options in drying technology which requires minimum labour and lowest maintenance costs.

SAKA’s Flash Dryers are user friendly and extremely easy to maintain. Here feed has very low residence time and dries instantly. Material dries as it is conveyed.

These Dryers are known for their superior product quality and reduces the risk of overheating. Flash Dryers are widely used in industries such as Agro-chemicals, food, minerals, dyestuff etc.

CAGE MILL FLASH DRYER

Consistent drying with economical drying process

Widely used for generation of dry powder, SAKA’s Spin Flash Dryers are known for consistent performance, sturdy design, and lower operating costs. Ideal for continuous operations these type of Flash Dryers are extremely fuel efficient and low at energy consumption.

In Spin Flash Dryers, viscous, paste or cake type of feed is introduced to dis-integrator which breaks the lumpy material. The disintegrated material is brought in contact of warm air which dries it instantly. Spin Flash Dryers are ideal for products such as fertilizers, pigment, dyestuff etc.

SAKA’s Spin Flash Dryers are compact in design and requires lesser space. These dryers meet all the pollution control norms and ensures clean environment.

Speedy drying for hard and lumpy material

SAKA’s Cage Mill Flash Dryers are ideal for hard or lumpy material. These Dyers are available in two options, Vertical pin, and Horizontal pin.

SAKA’s Cage Mill Flash Dryers are known for their thermal efficiency, longer service life and are extremely space efficient.

Cage Mill Flash Dryers have better crushing capacity required for lumpy or cake type material. The feed is introduced on the rotating cage where it meets warm air. The rotating cages breaks the lumps or cake and scatters the feed in the drying chamber leading to fast drying. Cage Mill Dryer facilitates easy drying without degradation of the feed.

SPIN FLASH DRYER

Consistent drying with economical drying process

Widely used for generation of dry powder, SAKA’s Spin Flash Dryers are known for consistent performance, sturdy design, and lower operating costs. Ideal for continuous operations these type of Flash Dryers are extremely fuel efficient and low at energy consumption.

In Spin Flash Dryers, viscous, paste or cake type of feed is introduced to dis-integrator which breaks the lumpy material. The disintegrated material is brought in contact of warm air which dries it instantly. Spin Flash Dryers are ideal for products such as fertilizers, pigment, dyestuff etc.

SAKA’s Spin Flash Dryers are compact in design and requires lesser space. These dryers meet all the pollution control norms and ensures clean environment.