FSD® Spray Dryer

Tried and trusted spray drying technology for food ingredients, coffee, chemicals, and pet food. 

The NIRO FSD® is a multi-stage spray dryer that combines spray and fluid bed drying technologies in a single unit. We’ve developed the system as an ideal option for processing free-flowing, dust-free, and easily reconstituted agglomerated powders. The combination of NIRO FSD® features, reliability and flexibility, together with GEA attention to detail and support, add up to great performance. Our customers around the world can have confidence in a versatile solution for processing a diverse range of powders, from agrochemicals and food flavors, to vitamins, proteins, maltodextrins, coffee and petfood. 

A spray drying solution tailored to your processes

We’ll never just sell you a system. Partner with us at GEA and we will sit with you to learn about your products and processes and understand your challenges and expectations. Then, together we can configure the best NIRO FSD® spray dryer that will meet current needs and help you achieve your goals, so you can expect top performance and great quality output, from day one, and for the lifespan of your plant. 

Key components of the NIRO FSD® platform, from the air disperser and spray drying chamber, to the cyclones, fluid bed and bag filters, can be tailored for each system, so every customer receives a personalized system. We’ll aim to maximize system efficiency and productivity, while staying in budget. 

Precisely defined powder characteristics

Whether you are new to our NIRO FSD® technology or you’re a long-term user, GEA experts can be with you on site or support you remotely to optimize key operating parameters for your spray drying process. Routinely evaluating operating parameters and making adjustments, if necessary, can help to ensure that your system is reproducibly processing powders with precisely defined characteristics, from particle size to powder solubility. And when you want to switch products or expand into new product types, we can offer in depth knowhow and advice to help you continue to get the best out of your spray drying plant. We may even be able to pilot test the process for your new product at our test center of excellence in Soeborg, Denmark, where you can also tap into a wealth of GEA expertise and knowledge. 

FSD® spray dryer features and benefits:

Spray and fluid bed drying integrated into one multi-stage drying system with excellent agglomeration performance

• Optional FSD-Granulator allows you to carry out additional agglomeration stage
• Individual FSD® components and final system tailored for each customer
• Flexible system design lets you process multiple products on one spray dryer
• Human-friendly operation and easy routine inspection make for a better working environment and shorter down time
• Thorough, automated cleaning frees operators to focus on other tasks

How it works

The multi-stage NIRO FSD® dryer can be set up to carry out up to three stages of drying, depending on the product. First, the liquid concentrate is atomized as it is fed through our high-pressure nozzles and sprayed directly into the drying chamber, where most of the water is evaporated as the droplets meet the hot air delivered via the air disperser. The product is then passed to the static fluid bed at the bottom of the drying chamber, where more of the remaining moisture is removed. From the static fluid bed, the particles are passed into the VIBRO-FLUIDIZER® for final drying and cooling. In parallel, exhaust air is conveyed through the cyclone to our SANICIP® II bag filter (for coffee processes exhaust air is passed through a TRH filter). The filtered powder fines are returned either to the static fluid bed, or to the air disperser or VIBRO-FLUIDIZER®, dependent on the required powder agglomeration profile. 

Additional agglomeration stage

We can give your plant further functionality by adding our FSD-Granulator to the NIRO FSD® spray dryer. The FSD-Granulator technology allows additional liquid to be added into the spray dryer’s stationary fluid bed to effect another stage of powder agglomeration. The introduced liquid might have the same composition as the feed itself, or be a solution of defined composition, or even water.

Hygiene and safety in powder processing, 24/7  

The NIRO FSD® spray dryer is hygienic by design and can meet all international regulatory requirements for chemicals, pharma and food processing. We can design your plant to include an automated clean-in-place (CIP) system that reduces the need for manual cleaning tasks. Automated CIP may also cut down on cleaning time, water and chemicals use, and so reduce costs associated with wastewater treatment. 

FSD® spray dryer plant upgrades

We want all of our customers to get great results from any GEA spray dryer. We’re always striving to develop new technologies that can improve your plant’s productivity, safety and efficiency, as well as support process sustainability goals. So, we turn our innovation into upgrades and options for our customers.

A key focus is always equipment safety and operational health and safety. For products posing fire or explosion risks GEA offers technologies such as process temperature monitoring, and our GEA SPRAYEYE®, and COTECTOR® systems, which minimize risk and support 24/7 production. Additional technologies, including our Fire Safety System and DRIVENT® explosion suppression vents, add further protection should an incident occur. 

A focus on spray dryer efficiency and quality

Integrating our optional Clean Purge and CEE cyclone technologies into the NIRO FSD® could further boost efficiency and quality. We’ve also shown that, when compared with other types of air disperser, the GEA DDD® air disperser distributes the drying air introduced into the chamber far more effectively, and with an optimized flow pattern. Benefits can include better overall equipment performance, a more uniform final product, and longer production runs between stops for cleaning. 

Technologies such as our SANICIP® II bag filter, our No Intervention Fines Return System (NIFRS) and 24/ feed system can further help to reduce product loss and potentially lead to real improvements in productivity and final powder quality. 

Options for stability and resource efficiency in spray drying

We know how important it is for every sector of industry to focus on improving process sustainability and reducing energy use and environmental impact. Take a look at our digital GEA OptiPartner advanced process control solution, heat recovery systems and energy-saving AddCool® heat pump technology, which in combination can help to dramatically improve process stability and energy efficiency for spray drying plants. Just talk to your local GEA representative to find out more.

Evaluate and test, before you invest

We’re more than happy for you to engage with our specialists to ask any questions about the NIRO FSD® spray dryer and related technologies.  At our test center of excellence in Soeborg, Denmark, you can also gain first-hand experience with our spray dryers, trial your processes on FSD® equipment, and work with our GEA experts to refine your processes. It’s a great opportunity to see additional GEA systems in action, and evaluate the best options for your plant, not just for today, but as you look to grow and expand.