Features of Pilotech Nano Spray Dryer
- High-efficiency electrostatic powder collector with up to 90% yield
- Micro-sample drying capability down to 30 mL volume
- GMP-compliant 316L stainless steel and borosilicate glass construction
- 21 CFR Part 11 compliance
- PLC touchscreen with real-time data logging
- Used by 6,000 research institutions, universities, and corporate laboratories worldwide
Your Leading Nano Spray Dryer Manufacturer
Whether in early-stage formulation research or pilot-scale R&D, nano spray dryers are essential specialized instruments for precision powder engineering. By tuning key process parameters like inlet temperature, feed flow rate, and electrostatic collector field strength, you can achieve your targeted specifications for particle size distribution, morphology, and high-yield product recovery.
Pilotech has 21 years of experience in the research, development, and manufacturing of laboratory equipment. Our products have been exported to more than 70 countries and regions, including the United States, Singapore, Germany, the United Kingdom, France, Australia, New Zealand, and Chile.
We offer open-loop and closed-loop nano spray dryers, providing safe and environmentally friendly drying solutions for both aqueous and organic solvents. If you have any special needs, please feel free to contact us. Our engineering team will provide you with a customized solution.
Uses ambient air for single-pass drying, venting exhaust directly. Cost-effective and simple to operate, suitable for non-toxic, water-based solutions, basic research, aqueous pharmaceuticals, and standard food-grade powders.
Recirculates inert drying gas like nitrogen in a sealed system, supporting solvent recovery. Protects the environment, reduces material costs, and provides safe processing for pharmaceuticals, organic formulations, advanced materials, and heat-sensitive compounds.
Nano Spray Dryer Specifications
| Parameter | Specification |
| Equipment Type | Laboratory Nano Spray Dryer |
| Atomization Technology | Vibrating Mesh / Fine Atomization |
| Atomizer Material | SUS316 Stainless Steel |
| Spray Mesh / Nozzle | Mesh Aperture Sizes: 4.0µm, 5.5µm, 7.0µm
Generated Droplet Range: 3µm to 15µm Final Dry Particle Size: 200nm to 5µm (Subject to feed concentration) |
| Drying Capacity | Up to 0.2 L/h water evaporation |
| Feed Rate | Approx. 10–200 mL/h |
| Minimum Sample Volume | Approx. 1–30 mL |
| Possible Particle Size | Approx. 0.2–5 µm |
| Droplet Size | Approx. 4–20 µm |
| Inlet Air Temperature | Ambient to 120°C |
| Outlet Air Temperature | Application-dependent |
| Drying Gas Flow Rate | Approx. 80–160 L/min |
| Drying Gas | Air / Nitrogen |
| Drying Gas Flow Pattern | Laminar, Co-current |
| Particle Collection | Electrostatic Particle Collector |
| Particle Collection Efficiency | Up to approx. 90% |
| Mean Residence Time | Approx. 1–4 s |
| Feed Pump | Peristaltic Pump |
| Feed Type | Solutions, Emulsions, Fine Dispersions |
| Maximum Feed Viscosity | Approx. 5–10 cP |
| Temperature Control Accuracy | ±1°C |
| Heating Power | Approx. 1.4–3.0 kW |
| Inert Gas Operation | Optional / Closed-Loop Configuration |
| Control System | Digital / Touchscreen Control |
| Typical Applications | Pharmaceuticals, Proteins, Enzymes, Nutraceuticals, Nanomaterials, Fine Chemicals |
| Scale | Laboratory R&D / Process Development |
Common Atomizers Used in Nano Spray Dryers
Different atomization methods are one of the key distinctions among various nano spray dryers. Therefore, the most important factor in selecting a nano spray dryer is finding the right nozzle.
Vibrating Mesh Nozzle Nano Spray Dryer
Working Principle
The vibrating mesh nozzle generates high-frequency vibrations that propel droplets through micron-scale mesh apertures. The liquid is squeezed to form micron- or submicron-sized droplets of highly uniform size, which become particles after drying.
Advantages and Disadvantages
This atomization method can achieve a very uniform droplet size distribution. Furthermore, because it does not involve high shear forces, the vibrating mesh nozzle is less likely to disrupt sensitive macromolecular structures. This method also offers high recovery rates for trace samples.
However, the mesh aperture is prone to clogging caused by high-viscosity liquids or suspensions containing large particles. Therefore, we do not recommend using this nozzle for high-viscosity materials. Furthermore, the meshes are consumables, and the cost of replacement is relatively high.
Suitable Materials
The vibrating mesh nozzle nano spray dryer does not generate high shear forces and is less likely to cause localized overheating, making it suitable for processing Proteins and Peptides. Low-viscosity aqueous polymer solutions are also well-suited for this method, as they can pass easily through the micropores and are less prone to crystallization and clogging.
You can also use it to process liposomes and colloids. The low shear force helps maintain the structural integrity of the colloids.
How to Adjust Particle Size
There are three main methods for adjusting particle size in a vibrating mesh nozzle nano spray dryer.
First, you can replace the mesh insert with one that has a different pore size. This directly determines the initial droplet diameter. Second, you can alter the solid content or solution concentration. After the solvent evaporates, the lower the concentration, the smaller the remaining dry solid particles will be. You can also control the atomization rate and droplet separation efficiency by adjusting the vibration frequency.
Two-Fluid Nozzle Nano Spray Dryer
Working Principle
The two-fluid nozzle relies on the collision of high-speed compressed gas with liquid at the nozzle outlet. The resulting powerful shear force can break the liquid stream into fine droplets, which then dry to form powder.
Advantages and Disadvantages
If your material is viscous, a two-fluid nozzle nano spray dryer is a good choice. This is because the powerful shear force can effectively handle high-viscosity liquids. However, two-fluid nozzles produce droplets with a wide size distribution. In some cases, the high shear force generated by the airflow may disrupt the biological structure of macromolecules.
Suitable Materials
The two-fluid nozzle nano spray dryer is suitable for processing poorly water-soluble APIs and small-molecule compounds, as it enables effective dispersion. Furthermore, because the channels are relatively wide, it is less prone to clogging when handling suspensions or substances prone to crystallization. You can also use this method for conventional heat-resistant polymer packaging materials with some viscosity, such as PLGA and PCL.
How to Adjust Particle Size
For two-fluid nozzles, the primary method for adjusting particle size is to change the GLR. Increasing the gas flow rate or reducing the feed rate can enhance shear forces to reduce particle size. Conversely, particle size will increase.
You can also use viscosity adjustment as a supporting method. Lowering viscosity reduces surface tension resistance, which facilitates fragmentation by the gas stream. In addition, you can replace the gas cap or liquid cap with one having a different nozzle tip size.
Ultrasonic Nozzle Nano Spray Dryer
Working Principle
The ultrasonic nozzle uses a high-frequency ultrasonic transducer to convert electrical energy into mechanical vibrations, causing capillary waves to form on the end face of the nozzle. When the amplitude reaches a critical value, droplets are ejected from the wave crests, resulting in atomization.
Advantages and Disadvantages
Because the ultrasonic nozzle operates at low velocity, it produces minimal splashing. Furthermore, this atomization method is less prone to clogging. And since it does not require high-pressure shear, it can help you reduce operating energy costs.
However, the initial droplets formed by ultrasonic nozzles are relatively large, and their effectiveness in atomizing high-viscosity liquids is limited.
Suitable Materials
Ultrasonic nozzle nano spray dryers are ideal for processing heat-sensitive active ingredients. Because they generate no heat from intense friction and do not subject the material to high shear forces that could damage macromolecular structures.
However, if your material has high viscosity, using this method may cause the nozzle to clog. They are better suited for processing low-viscosity materials.
How to Adjust Particle Size
You can change the droplet size by adjusting the ultrasonic frequency. The higher the frequency, the smaller the resulting droplets.
In addition, you can adjust the solution concentration to reduce surface tension. This helps form smaller capillary waves, resulting in smaller droplets.
Nano Spray Dryer Maintenance
Nano Spray Dryer Maintenance can be categorized into daily/per-run, periodic, and annual.
Daily or Post-Run
You need to clean the atomizer promptly after use, especially the vibrating mesh nozzle. Clean it in an ultrasonic bath using deionized water or a mild solvent to prevent solute crystallization from clogging the orifices.
You should also clean the collector and glass chamber. The plates of the electrostatic precipitator must be wiped clean to remove residual powder, preventing cross-contamination or electrical short circuits. In addition, flush the tubes with purified water or a solvent to prevent sediment buildup.
Monthly or Quarterly
You need to inspect the flexibility and wear of the peristaltic pump tubing and replace it promptly. This prevents inaccurate feed flow rates caused by thinning of the tubing walls. Additionally, inspect the electrostatic precipitator plates and high-voltage module to verify whether the insulating components have aged or show signs of breakdown.
The sealing performance of the dryer is also important. Be sure to inspect the O-rings at the glass joints. If they are hardened or deformed, replace them promptly to ensure the system remains airtight.
Annual Service
You need to replace the HEPA/ULPA filters at the air inlet and outlet annually. This helps keep the incoming air sterile and prevents the leakage of nanopowder in the exhaust gas. You also need to calibrate the inlet temp, outlet temp, and differential pressure sensors.
If you are using a closed-loop nano spray dryer, you should also check the accuracy of the oxygen concentration sensor and the cooling performance of the condenser.
Nano Spray Dryer Installation
Installation Preparation and Environment Requirements
Nano spray dryers must be installed inside a fume hood or in an environment equipped with local exhaust ventilation to prevent the inhalation of nano powders. If your material contains organic solvents, the equipment must be installed in an explosion-proof environment.
In addition, a gas supply that meets applicable standards is required. A dry, oil-free supply of high-pressure nitrogen or compressed air must be provided, and the gas pressure and purity must meet the specified standards.
Installation Process
First, place the main unit on a level laboratory bench free from vibrations. Next, install the drying chamber, tube, and electrostatic collection device. Tighten the hand-tight flanges to keep a proper seal.
Then you should connect the inlet and exhaust pipes and the cooling water circulation unit (if organic solvent recovery is involved). Connect the temperature probe, the electrostatic high-voltage cable, and the control panel.
Finally, conduct a gas leak test to verify the system’s airtightness. Run a no-load program to verify that the heater, fan, and atomizer are functioning properly.
You Can Use Nano Spray Dryer For:
| Application | Nano Spray Dryer Advantages | Specific Applications |
| Pulmonary Drug Delivery | Pulmonary drug delivery requires extremely small particles (typically 1–5 µm) and distributed with high uniformity. A nano spray dryer can generate ultra-fine and monodisperse particles, significantly increasing deep lung deposition rates. | Dry Powder Inhalers (DPI), including inhaled insulin and inhaled antibiotic powders. |
| Improving Bioavailability of Poorly Soluble Drugs | BCS Class II/IV drugs have poor water solubility, resulting in low absorption rates. A nano spray dryer can convert drugs into nano-scale amorphous solid dispersions (ASD), drastically increasing specific surface area and dissolution rates. | Nanocrystal drugs, encapsulation of poorly soluble anti-cancer drugs. |
| Biologics and Vaccine Stabilization | Ultra-fast thermal drying avoids thermal degradation, providing quick, single-step powderization to boost ambient storage stability. | Enzymes, antibodies, mRNA-LNP formulation drying. |
| Nanocapsules and Targeted Carriers | Low-shear atomization combined with high-precision phase separation encapsulation improves drug loading and sustained-release profiles. | PLGA/Chitosan nanoparticle encapsulation, targeted liposome powderization. |
| High-Value API Early-Stage R&D | Micro-sample feed design (experiments can run with as little as 1–5 mL) and electrostatic collection yields reaching 70%–90%. This helps reduce your costs. | Rare natural product extracts, early New Chemical Entity (NCE) screening. |
| Food and Nutraceutical Encapsulation | Low-temperature rapid drying protects heat-sensitive compounds and creates nano-encapsulated powders for enhanced stability and controlled release. | Omega-3 powder, microencapsulated probiotics. |
| Advanced Chemical and Battery Materials | Nanoparticles can increase specific surface area and shorten ion diffusion paths, boosting electrochemical kinetics and conductivity. | Lithium battery cathode precursors, nano catalysts, ceramic powders. |
Factors Affecting the Price of a Nano Spray Dryer
Atomization Technology
Different atomizers can have a significant impact on the price of a nano spray dryer. Spray dryers equipped with a high-precision vibrating mesh system are very expensive. In contrast, equipment with a two-fluid nozzle offers better value for money.
Electrostatic Precipitator Efficiency
The voltage stability, arc-suppression design, and high recovery rate technology of high-voltage electrostatic precipitators are among the key cost factors.
Organic Solvent Capability
If you need to use organic solvents, the inclusion of explosion-proof design, a closed-loop system, oxygen concentration monitoring, and a condensation recovery system will significantly increase the cost.
Data Compliance
The software permission management, audit trail, and electronic signature features required by pharmaceutical companies increase software development and certification costs.
Materials of Construction
Compared to more common materials, the use of high-purity borosilicate glass, titanium alloy, or 316L stainless steel increases hardware costs.
How to Choose a Suitable Nano Spray Dryer?
Selecting an Atomizer Based on Material Characteristics
First, you need to select the appropriate atomizer based on the characteristics of the material. If you need to process biomacromolecules or require an extremely narrow particle size distribution, you could choose a vibrating mesh nozzle. If you are processing conventional suspensions that are highly viscous or prone to crystallization, a two fluid nozzle is a better choice.
Specify the Solvent Type
The type of solvent you use significantly affects the selection of a nano spray dryer. If you are using only aqueous solutions, a basic open loop structure is suitable. If organic solvents such as ethanol or acetone are involved, an explosion-proof inert loop system must be installed.
Evaluating Sample Volume and Recovery Rate Requirements
If you are in the early stages of R&D and have an extremely small sample volume, you must consider the nano spray dryer’s minimum dead volume and electrostatic collection efficiency. Otherwise, the equipment may be unusable or result in significant material loss.
Industry Compliance Requirements
For universities and research institutions, the focus is generally on the cost-effectiveness and operational flexibility of nano spray dryers. However, if you are a pharmaceutical company, you should verify that the equipment complies with 21 CFR Part 11. It should also include complete DQ/IQ/OQ validation documentation.
To prevent clogging in a nano spray dryer, both the material and the operating conditions must be considered. First, control the feed viscosity and filter the material thoroughly to confirm that the diameter of the suspended particles is smaller than the nozzle orifice. Second, reduce the solution’s solids content or appropriately increase the feed temperature. This will lower the surface tension and viscosity. Clean the equipment promptly after the experiment to prevent crystallization and residue buildup inside the microporous structure.
When your research and development involves high-value-added, highly heat-sensitive materials, or extremely small sample quantities, you should primarily use a nano spray dryer. Examples include the development of dry powder inhalers (DPIs) for pulmonary delivery (requiring particles of 1–5 µm), nano-amorphous dispersions to improve the bioavailability of poorly soluble drugs, or the processing of early-stage API samples weighing only a few milligrams.
The key to improving the recovery rate of a nano spray dryer lies in improving the drying and electrostatic collection conditions. You can adjust the inlet temperature and feed rate, making the droplets thoroughly dried before they come into contact with the chamber walls to prevent them from sticking. Second, keep the high-voltage field strength of the electrostatic precipitator stable. The electrodes must be kept clean and dry to enable efficient deposition of fine particles on the collection electrodes and reduce losses due to entrainment in the exhaust gas.
The two-fluid nozzle relies on high-speed gas flow to shear and atomize the spray, which may affect the conformation of sensitive proteins. However, by adjusting the process parameters, it is still possible to effectively protect biomacromolecules. By using protectants like trehalose and optimizing the gas-to-liquid ratio, you can reduce shear damage and properly preserve the activity of proteins and vaccines.
Electrostatic particle collection technology is based on the principle of charge migration in a high-voltage electric field. After drying, submicron particles are carried by a laminar airflow into a high-voltage electrostatic precipitator, where they become charged in the corona discharge zone. Driven by strong electric field forces, the charged particles migrate toward collection plates of opposite polarity and are deposited there. This technology overcomes the low capture efficiency for particles smaller than 2 μm of traditional cyclone separators and enables the efficient recovery of nanopowders.
Nano spray dryers are fully capable of supporting long-term continuous R&D operations, provided that the process parameters remain stable. Our nano spray dryer is equipped with a constant-speed peristaltic pump and a continuous temperature control system. They help keep uniform feeding and drying over extended periods. We recommend selecting wear-resistant pump tubing and monitoring the atomizer for minor blockages caused by material deposits. Additionally, be sure to unload the electrostatic collection plates regularly to maintain an efficient electric field.
During the scale-up process, the gas-to-liquid ratio (GLR) and relative jet velocity should be kept constant. This helps maintain the initial droplet size distribution. At the same time, the volume of the evaporation chamber and the hot air circulation flow rate must be scaled up proportionally and simultaneously to keep the droplet drying trajectory and residence time consistent with those of the pilot-scale test.
Yes. Complete DQ/IQ/OQ documentation packages are available. We also provide FAT/SAT support to ensure compliance with cGMP standards. If you have any other compliance requirements, we can accommodate them as well.