Industrial Spray Dryer Capacity
When it comes to producing high-quality powders at industrial volume, consistency and control are non-negotiable. At Advanced Powder Dynamics, we provide industrial spray drying solutions that adapt to your needs. Whether you’re handling simple ingredients or sensitive, high-value formulations, our systems deliver precision and repeatability at each stage of production.
Backed by decades of expertise and our proprietary dynamic atomization process, we offer flexible industrial spray dryer capacity that supports product development, scale-up, and long-term production. We have worked with over 300 ingredients, including heat-sensitive materials like proteins, yeasts, vitamins, and egg whites, to deliver results that match or exceed freeze-dry-like quality.
Flexible Industrial Spray Dryer Capacity
Our facility is designed to support a wide range of batch sizes and formulations. Our spray dryers offer R&D and pilot trials for development or low-volume campaigns, as well as large-scale production for bulk output. Our contract manufacturing and toll processing service is built for repeatability, efficiency, and scalability.
Our production capability includes:
| Dryer Type | Evaporation Rate | Batch Size (Wet) | Drying time (Estimated) | Usage |
| R&D Dryer (DA-5) | 5 lb/hr | 6–12 gal (50–100 lbs) | 3-5 days | Formulation trials, testing (Low volume production) |
| Pilot Dryer (DA-50) | 50 lb/hr | 55–300 gal (450–2500 lbs) | 3-5 days | Optimization, validation (Low to medium volume production) |
| Production Dryer (DA-500) | 500 lb/hr | 1,200-5,000 gal (10,000-42,000 lbs) | 7-14 days | Full-scale manufacturing (Medium to high volume production) |
Note: The DA-500 production dryer can also handle 2x and 3x volumes as needed. The drying times are approximate and depend highly on the quantity and input material.
We operate on the basis of highly optimized logistics and scheduling plans to minimize downtime and ensure seamless flow of material. Customers are kept in the loop at all times regarding status and progress.
See APD in Action
Cambrooke had a unique market opportunity when a competitor recalled their amino-acid-based, hypoallergenic medical food, and they needed a partner to help quickly scale production of a powdered fat ingredient. The APD research and development team quickly responded to help fill this critical market gap.
Contract & Toll Manufacturing Services
At Advanced Powder Dynamics, we offer more than just a production facility. We work as a true extension of your team, providing support from product development to full-scale production. At our fully equipped facility, you can be assured that your powder product is developed, scaled, and packaged with expert precision.
We provide support with:
- Liquid-to-liquid and powder-to-liquid blending
- pH adjustment, emulsions, and homogenization
- Heating and cooling (40°F–180°F)
- Custom powder packaging (paper bags, fiber drums, super sacks, etc.)
- Material receiving in drums, totes, and bulk tankers
- cGMP-certified
- Kosher and Halal supervision, as needed
- USDA Organic-certified runs
Advanced Process Control for Better Powder Products
What sets us apart is our patented Dynamic Atomization Technology that delivers ultra-fast drying (≈ 0.5 second) with minimal thermal stress. Unlike traditional systems that are mechanically intensive, our dynamic atomization process uses a high-velocity, low-pressure air stream that creates consistent droplet sizes and rapid evaporation, which is especially suitable for sensitive ingredients. This results in:
- Superior powder stability and functionality
- Enhanced bioavailability and solubility
- Better protection for heat-sensitive ingredients
- Freeze-dry-like quality
- Particle encapsulation for odor, taste masking, and nutrient preservation
For advanced cyclodextrin encapsulation, you can also get access to our CyLocⓇ–DexKeyⓇ inclusion and delivery technologies to support stability and controlled release of the ingredient.
Whether you aim to achieve a target particle size, consistency, solubility, or active ingredient retention, our team at Advanced Powder Dynamics is here to meet all your powder particle engineering specifications.
The Industrial Spray Dryer Capacity You Need
Whether you’re entering the market or simply want a trial run, let Advanced Powder Dynamics handle your precision powder production. From food and nutraceuticals to feed and specialty applications, our in-house team of experts, proprietary technologies, and industrial spray dryer capacity are built to meet your product and scale requirements.
To learn about our flexible industrial spray dryer capacity, contact us or call (928) 492-4040.