I. Core Applications: Guardians of Heat-Sensitive Materials
The core value of low-temperature spray dryers lies in their ability to directly convert solutions, emulsions, or suspensions into dry powder in a very short time, while maximizing the protection of the material's biological activity or chemical structure. Its main application areas include:
(1) Biopharmaceuticals and Health Products: This is its most typical application scenario. It is used to dry heat-sensitive enzymes, probiotics, antibiotics, proteins, peptides, vaccines, and various plant extracts. The low-temperature evironment effectively prevents the inactivation and denaturation of these active ingredients, ensuring the efficacy of the final product.
(2) Advanced Food Industry: Used to produce functional food powders rich in active ingredients, such as freeze-dried royal jelly powder, spirulina powder, and certain fruit juice powders, to retain their natural flavor, vitamins, and antioxidant components.
(3) Nanomaterials and High-Tech Ceramics: Used to prepare ultrafine powder precursors with uniform particle size distribution and precise chemical composition control. These powders can form high-performance ceramic materials after sintering. (4) Fragrance and Flavor Industry: Through microencapsulation technology, volatile fragrances are encapsulated in the wall material. Low-temperature drying effectively prevents aroma loss, producing highly stable solid fragrances.
II. Systematic Maintenance: Key to Stability and Longevity
Low-temperature spray dryers are complex systems integrating fluid mechanics, heat and mass transfer, and electrical control. Their maintenance must follow systematic principles.
Daily Maintenance (After Production)
(1) Cleaning: This is the most important daily operation. Immediately rinse the material tank, atomizer, and conveying pipeline with warm water or a suitable solvent to prevent residues from drying and scaling, clogging the precision nozzles.
(2) Cleaning the Drying Chamber and Cyclone Separator: Remove powder adhering to the walls. Check if the cyclone separator discharge port is unobstructed.
(3) Draining Waste Liquid: Empty the peristaltic pump pipe and drain the wastewater from the condensate collection bottle.
Regular Maintenance (Weekly/Monthly or by Operating Duration)
(1) Inspection and Replacement of Wear Parts:
① Atomizer: Check the wear condition of the nozzles. Wear will lead to poor atomization and uneven particle size, requiring timely replacement.
② Sealing Rings: Check the sealing rings at all pipe connections and doors for aging or damage to ensure system airtightness and prevent powder leakage or moisture absorption.
③ Peristaltic Pump Tubes: Long-term pressure will cause fatigue deformation, affecting feeding accuracy, requiring regular replacement.
④ Filters: Clean or replace the high-efficiency air filter at the air inlet and the dust filter at the air outlet to ensure smooth airflow and environmentally friendly emissions.
(2) System Performance Verification: Regularly check and calibrate key parameters such as temperature sensors, pressure gauges, and peristaltic pump flow rates to ensure process repeatability.
Seasonal/Annual Maintenance
(1) Thorough Cleaning of Heat Exchangers: Purge with compressed air or rinse with a special cleaning agent to ensure heat exchange efficiency and save energy.
(2) Electrical System Inspection: A professional electrician will inspect the connections and insulation of electrical components such as the fan, heater, and control cabinet to eliminate potential safety hazards.
(3) System Leak Detection: A pressure test will be conducted on the gas system to check for leaks.
III. Conclusion
Low-temperature spray dryers are key equipment for pulverizing high-value-added heat-sensitive materials. Users not only need to deeply understand their unique application in protecting active ingredients, but also need to integrate systematic and preventative maintenance concepts into their daily operating procedures. Only through meticulous care can this precision equipment continuously produce high-quality powders, while maximizing its service life and providing stable and reliable support for research and development and production.