Packaging
Cameras Help Spray Dryers Perform Better, Safer and More Efficiently
Wednesday 11. March 2009 - GEA Niro in Copenhagen has developed a revolutionary system to monitor the performance of spray nozzles in its dryers, using TV cameras.
The cameras show a continuous picture of the spray zone allowing operators to ensure that there are no leaks or any build-up of solid matter and that the spray dispersal within the drying chamber remains at an optimum level. Furthermore it is possible with the cameras to monitor if the high pressure shut off valves are leaking. This helps avoid unnecessary shut downs, improves product quality and reduces the risk of heat build up within the chamber.
It’s essential to ensure that nozzles in spray dryers are free from leaks that can disrupt the droplet dispersal within the chamber and that there is no build up of solid matter that can make the chamber overheat and, in extreme cases, may even cause fire and an explosion.
In the past this was impossible to do while the spray dryer was running as the spray nozzles are fully enclosed in the drying chamber. The new system, however, allows operators to watch the mist emerging from the nozzles and identify any abnormalities immediately. They can then intervene if necessary to take corrective action – but only when it’s needed. Unnecessary shut downs are eliminated.
Gerhardt Jacobsen, Safety and Environmental Resource Manager for Niro’s Food & Dairy Division explained that the new system is particularly useful for detecting leaks from nozzle gaskets during production and from the nozzle itself during the start up and shut down of the spray drying equipment. “By watching the way the nozzle behaves during every stage of the process we can minimize fouling of the drying chamber and help avoid safety issues, such as fire and explosions.”
The camera also allows operators to monitor the fines in the spray zone to ensure the best possible product quality.
A further development of the technology is expected later this year that will allow automatic monitoring of the camera image. This will allow the spray dryer to be shut down automatically if a risk of explosion arises.
Niro is the world’s leading manufacturer of spray drying equipment for the food industry and a member of the P-Division of the GEA Group.