Retrofitting and or Upgrading your Existing Drying Plant

Are you getting the most out of your Investment on Evaporation and Drying Equipment? Do you get desired Particle size, Bulk Density, Flowability and required attributes of the product? RAYGM helps you maximize the return on your Evaporator and Drying Equipment assets by untapping the hidden potential in your Liquid and or Powder processing Plant and streamline your operation more advanced ways.

The Unlocking true potential of your existing Liquid to Powder processing plant.

Today the industries are competing harder than ever before to sustain and expand their positions in competitive markets. Many manufacturers are looking to modernize their powder production plant in order to provide products with specific functional properties in response to ever more demanding customers and market requirements.
The latest process plant design and equipment offered by RAYGM are having wide range of benefits in terms of Cost of Drying (per Kg of product), Production Rate, Energy Efficiency, and Powder Quality Attributes that are important to maintain existing customers, add new segment of markets / customers and keeping margin in earnings.
The Investment, statutory approvals and lead-time required for building new Liquid to Powder Processing Plant may make this option less attractive for manufacturers looking to maximize return on investment, minimize capital outlay and secure fast delivery time of product to market. By giving a chance to RAYGM, you can achieve all of the benefits of a new plant in short period of time and at a significantly lower investment by retrofitting and upgrading your existing liquid to powder processing Plant.

Operational Benefits of Retrofitting and Upgrading your existing Plant

  1. Lower drying cost per kg of product through increased production rate and lower energy consumption.
  2. Greater return on existing and new investment.
  3. Increased safety of the personal and equipment.
  4. Shorter pay back periods for the new investments.
  5. Short implementation time , reduces production loss and revenue, earnings etc.
  6. A plant producing a greater variety of products opens a wide range of opportunities.
  7. Higher quality produced powders earn premium prices in the market and open new avenues for New earnings opportunities.
  8. Reduced manpower for cleaning and downtime by installing CIP (Cleaning-In-Place) systems.
  9. Reduced downtime and operational costs through lower maintenance requirements due to upgraded equipment.
  10. Higher production and energy efficiency and less waste, emissions through automated plant control.

Upgrade Options

There are numerous opportunities for improvements in most existing liquid to powder drying plant in order to ensure compliance with new environmental and statutory regulations, heat recovery, increase production capacity, reduce cleaning downtime and manpower etc. The best result depends, however, on choosing the solution that best meets your needs with regard to market requirement, production capacity, product quality, drying cost, payback period, rate of return on investment etc.

Conversion of Single Stage Spray Dryers to Multi-stage Spray Dryers.

Conversion of Single Stage Spray Dryers to Multi-stage Spray Dryers.

Conversion of Single Stage Flash Dryers with Multi-Stage Flash + Fluid Bed Dryers.

flash-dryer

Installation of Bag Filter in Existing plant

Powder yield and Environmental considerations often require the installing of a bag filter. Today, a bag filter is normally installed after the cyclones in order to reduce costs and collect residual powder, reducing emissions after the filter to 20 mg/m3. In many instances where the product is again blended to have uniform particle size and bulk density, Cyclones can be eliminated and reduce the plant power consumption by around 10%.

Installation or Direct or Indirect Hot Air Generator

An older steam air heater can be converted into a direct gas or Indirect oil or coal fired air heater, thus eliminating the need for purchasing a new high-pressure steam boiler. This can also provide an increase in drying air temperature, resulting in a higher plant capacity. The typical maximum inlet temperature with steam air heater is 190°C. This can be raised to 280°C using direct or indirect hot air generators, resulting in a plant capacity increase of some 30% and the drying cost decrease by some 20%.

Installation of A Recuperator

A recuperator can be installed at the outlet of Indirect Oil or Gas Fired Hot Air generator to reduce fuel consumption by some 10 to 30% depending upon the outlet air temperature from hot air generator.
Similarly, a recuperator Gas or liquid can be installed at the outlet of drying unit to recover heat from outgoing exhaust air.
If you think we can help you any way get in touch with us.