The patent-pending PolarDry® Electrostatic Spray Dryer utilizes revolutionary electrostatic technology which drives water to the shell and active to the core, lowering the evaporation temperature and eliminating active ingredient loss, degradation, or denaturalization. Harnessing the electrostatic effect, the dispersed active driven into the core is microencapsulated, virtually eliminating surface active, resulting in stunning encapsulation efficiency.
A portable PLC controlled once-through design intended for small-scale feasibility tests. This GMP designed machine is specifically sized to fit in most lab & fume hoods.
A portable PLC controlled once-through design intended for a laboratory environment. This GMP designed machine is the best option for feasibility checks.
A semi-portable PLC controlled recirculating system for R&D Environments. This unit uses the same nozzle as Models 032 and 050+ for easy scale-up. This model includes portable access stairs with a work platform.
Model 032 is a modular design, PLC controlled system for Pilot Environments. Choose from Batch ArchitectTM or Batch Architect ProTM with CFR 21 PART 11 Compliant Data Logging to control this intermediate system. This model includes access stairs with a work platform.
Electrostatic Spray Dryer Specifications
|Model||Model 0.1||Model 001||Model 004||Model 032||Model 050||Model 100||Model 200|
|Nom. Evaporation Rate (kg/hr)||0.1||1||4||30||50||100||200|
|Min Drying Temp. (°C)||20*||20*||10||10||10||10||10|
|Max Drying Temp. (°C)||200||140||140||140||140||140||140|
|Max Drying Gas Flow (m3/hr)||8.5||42||170||1020||1784||3568||7136|
|Max Atomizing Gas Flow (m3/hr)||3||10||17||68||120||240||480|
|Collection Volume (liters)||0.25||1||20||14**||20**||20**||20**|
|Drying Gas Heater||Electric||Electric||Electric||Electric||Indirect Gas||Indirect Gas||Indirect Gas|
|Gas Handling||Once Through||Once Through||Recirculating||Recirculating||Recirculating||Recirculating||Recirculating|
|Feed Stock Pump|
|Nozzle Clog Monitoring||-||-||-|
|WIP Nozzles Included||-||-|
|Filter System||Patent Pending Filter Bag||Patented Reverse Pulse Bag||Patented Reverse Pulse Bag||Reverse Pulse Cartridge||Reverse Pulse Cartridge||Reverse Pulse Cartridge||Reverse Pulse Cartridge|
|Controls||NEMA 4X||NEMA 4X||NEMA 4X||NEMA 4X||NEMA 4X||NEMA 4X||NEMA 4X|
|Controls Software||Batch Architect||Batch Architect||Batch Architect||Batch Architect***||Batch Architect***||Batch Architect***||Batch Architect***|
*Dependent on inlet gas temperature **Pneumatic or Cable Conveyor Available ***Batch Architect ProTM available for CFR21 Part 11 Compliance
Our spray dryers utilize electrostatic technology to drive water to the outside of the droplet allowing us to dramatically lower operating temperatures from the traditional ~200 °C to ~80 °C. This lower temperature allows for greater encapsulation efficiency for high-volatile components and reduces heat degradation of molecules/components.
PolarDry® all-in-one systems feature small footprints which reduce maintenance and installation costs. They feature a disposable inner liner making for easy clean-up/changeover. The complete product line is scalable from R&D to production-sized models.
PolarDry machines are virtually dust free. Each negative pressure spray chamber has inflatable seals with alarms if seal pressure is not met. All finish material is collected in a centralized collection system (no cyclones or dust collectors required) and finished material is removed using a sealed conveying systems. Particle separation filters are high efficiency with a dust sensor on the exhaust system and HEPA filters on the inlet and exhaust. The whole spray chamber comes with Wash-In-Place tank cleaning nozzles so that any dust remaining in the vessel can be cleaned prior to opening up the vessel.
Our nitrogen inerted systems are SAFE! Process gas is recycled virtually eliminating regulatory issues regarding negligible emissions.
PolarDry’s patent pending liner system has several benefits key to the operation of the electrostatic spray dryer technology as well as making operation, clean up, and change over simple. The FDA compliant liner is inserted in the spray chamber from the top and covers the vessel walls from top to bottom. This forms a thermal barrier that insulates the vessel walls preventing heat loss to the process room and faster warm-ups. The liner may be washed using tank cleaning nozzles then removed for product change over if required. For difficult to clean products, like those containing lipids, the liner may simply be removed and discarded.
All polar dry nozzles are designed by Spraying Systems Company, Experts in Spray Technology. Each nozzle is precision machined to high tolerances to assure consistent droplet formation, fully analyzed and supported by the Spraying Systems organization assure a high level of technical support, droplet data and analytical support. The PolarDry nozzles are designed for reliable service, safety, and consistency especially for electrostatic spray drying technology.
By controlling the electrostatic charge applied to the feed on an intermittent basis, PolarDry® Technology gives you the means to agglomerate particulates as they are being dried. This patent pending feature, PWM (Pulse Width Modulation) precludes the need for expensive secondary agglomeration operations.
By controlling the voltage applied to the spray droplet as it is being atomized, some particles form an outer shell readily while others develop their shell gradually resulting in a wet or tacky particle. As these two types of particles colloid, they bond forming an agglomerated particle. This results in a finished product with larger particles and fewer fines which flow freely.
As the FDA and other worldwide regulatory agencies are pushing continuous process in the production of pharmaceuticals, the PolarDry® process stands ready to meet the requirements. PolarDry® machines incorporate a unique patent pending collection/particle separation plenum that can be easily configured for batch or continuous processing by configuring the outlet as shown above.
Flexibility is a key consideration when developing your process. PolarDry® machines are designed to ensure:
How PolarDry® Works
Fluid Air Process Engineer, Joel Migchelbrink, describes the basic process and unique feaures of the award-winning PolarDry® Electrostatic Spray Dryer.
Witness the hydration difference between identical emulsified feedstocks dried with traditional spray dry technology versus PolarDry electrostatic technology.