polardry electrostatic spray dryer

Introducing the Future of Spray Dry & Microencapsulation

The patented 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.

Model 0.1

PolarDry model 0.1

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.

Model 001

PolarDry model 001

A portable PLC controlled once-through design intended for a laboratory environment. This GMP designed machine is the best option for feasibility checks.

Model 004

PolarDry model 004

A semi-portable PLC controlled recirculating system for R&D Environments. This unit uses the same nozzle as 032 and 050 to simplify the typical development work required to scale up from one machine to the next. This model includes portable access stairs with a work platform.

Model 032

PolarDry model 032

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

*Dependent on inlet gas temperature **Pneumatic or Cable Conveyor Available ***Batch Architect ProTM available for CFR21 Part 11 Compliance

The PolarDry® Difference

Low Operating Temperature

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.

All-In-One Design

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 and/or changeover. The complete product line shares many similarities simplifying the typical development work to scale up from one machine to the next.

Environmentally Friendly

Our nitrogen inerted systems are SAFE! Process gas is recycled virtually eliminating regulatory issues regarding negligible emissions.

Dust Free

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.

 Liner

PolarDry’s patented 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.

Unique Nozzle Design

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.

Granulating While Drying

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 patented feature, PWM (Pulse Width Modulation) precludes the need for expensive secondary agglomeration operations.

PolarDry side-by-side comparison

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.

batch configuration vs. continuous vacuum transfer system

Configurable in a Batch or Continuous Process

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 patented collection/particle separation plenum that can be easily configured for batch or continuous processing by configuring the outlet as shown above.

Flexible Solution

Flexibility is a key consideration when developing your process. PolarDry® machines are designed to ensure:

  • Quick Set Up from one run to the next by integrating in the design a disposable inner chamber liner that can be changed in a matter of minutes.
  • Patent pending cartridge filter configuration that allows easy turnaround from one run to the next. The reverse pulsing feature ensures that drying gas flow remains steady.
  • Portability so machines can be easily transferred from one suite to another:
    • Model 001 and Model 004 are on wheels and fully contained, only requiring electricity, a Nitrogen intake, and an outside chiller (Model 004 only) to operate.
    • Model 032 only requires electricity, a Nitrogen intake, and an outside chiller to operate.
orange triangle with exclamation mark

Safety Features

  • Nitrogen Inerting/Explosion Protection
  • Redundant oxygen monitor prevents operation if oxygen level is too high
  • Rated lid safety lock & monitored inflatable seals prevent the operator from opening the vessel lid if oxygen level isn’t safe (Model 004 and above)
  • Heater over temperature protection
  • Emergency stop buttons and monitoring with safety reset Voltage generator resets if amperage exceeds 8 mA, protecting the operator
  • Area oxygen monitoring

Customize Your System

Available Options

  • Explosion Proof Solvent Capable System
  • Prepackaged Chilled Water Systems
  • Batch Architect Pro CFR 21 PART 11 compliant recipe based control systems
  • Material Conveying Systems
  • Remote Control System Access

Smash N' Spray

Spray Drying Technology has been in use on an industrial scale for over a century. This involves an assemblage of particles adhering to one another, a process referred to as agglomeration. The goal of this process is microencapsulation. In Electrostatic Spray Drying, a near-perfect encapsulation of the active ingredient is achieved without the usage of high-temperature evaporation.
Let's get in touch Contact Us