LPG-150 Spray Drying Machine with ≥95% Powder Collection Efficiency

Every kilogram of powder that escapes the exhaust is money lost and a compliance risk. Collection efficiency is where a spray drying machine earns its keep, because fines lost to the filter are product you already paid to dry. The LPG-150 uses a staged recovery train to keep more than 95% of solids in the bag.

The Problem Customers Report

Operators see low powder yield: material goes in, far less comes out, and the gap is lost as airborne fines.

Visible dust in the exhaust is both a product loss and an environmental problem that can breach emission limits.

Low yield quietly inflates the true cost per kilogram, so competitive quotes look better on paper than the real running cost.

Why It Happens

A single cyclone is efficient only above a certain particle size. Fines below about 10 μm follow the gas stream instead of spinning out, so they escape.

High gas velocity through the cyclone scours collected powder back into the airflow, reducing real recovery.

Leaks and poor sealing at the discharge let captured powder re-entrain, undoing the cyclone's work.

Our Solution

We combine a high-efficiency cyclone with a downstream bag filter. The cyclone grabs the bulk, and the bag filter captures the fine fraction the cyclone misses, pushing total recovery above 95%.

The bag filter uses pulse-jet cleaning so it stays open and does not choke, keeping pressure drop and energy use low.

Arc-butt pipe joints, sealed flanges and a rotary discharge valve stop re-entrainment, so captured powder reaches the collection point instead of the filter.

A differential-pressure gauge on the filter gives a live efficiency readout, so operators know instantly if recovery drifts.

Application Scenarios

It is essential for high-value powders where losing a few percent is significant, such as pharmaceutical and nutraceutical ingredients.

It suits food and dairy plants that must meet strict dust-emission limits while maximizing yield.

It also fits chemical catalysts and pigments, where expensive fines must be recovered rather than vented.

Specifications

How to Choose the Right Model

Base your model size on solids throughput, not liquid throughput. Higher feed solids deliver more powder per hour for the same evaporation.

If your product has a large fine fraction, the bag filter stage is essential; a cyclone alone will not hit 95%.

For sticky powders, ask for a jacketed or heated cyclone to prevent bridging at the discharge.

Confirm your local emission regulations, then choose a filter media grade that meets them with a safety margin.

FAQ

Q: What collection efficiency is realistic?

A: With the cyclone plus bag filter train, ≥95% is standard, and well-tuned units on favorable powders exceed 97%.

Q: Will the bag filter clog quickly?

A: No. Automatic pulse-jet cleaning keeps the media open; differential pressure typically stays in the 0.6-1.5 kPa range.

Q: Can I recover the fines as usable product?

A: Yes. The bag filter discharge is collected and can be re-dried, blended or sold, depending on your specification.

Q: How much does higher recovery save?

A: Recovering an extra 5% on a 200 kg/h powder line keeps roughly 10 kg/h in the bag, which often pays back the filter cost within a year.

Send us your solids rate and particle size, and we will size a spray drying machine and recovery train that keeps at least 95% of your powder in the bag.