Pilotech YC-2100 Pilot-Scale Vacuum Spray Dryer

Overview

The Pilotech YC-2100 Pilot-Scale Vacuum Spray Dryer is an engineered solution for laboratory-to-pilot transition of thermally sensitive, oxidation-prone, and biologically active materials. Unlike conventional atmospheric spray dryers, the YC-2100 operates under controlled vacuum conditions (−0.05 to −0.08 MPa), enabling rapid solvent evaporation at significantly reduced thermal load. This vacuum-assisted drying principle leverages the depression of boiling point under sub-atmospheric pressure—allowing aqueous feed solutions to undergo atomization and drying at temperatures as low as 50 °C while maintaining high throughput (up to 3000 mL/h). The system employs a coaxial two-fluid nozzle design, ensuring symmetrical droplet formation and eliminating wall impingement—a critical factor in achieving consistent particle morphology and minimizing thermal degradation during drying. Its all-316L stainless steel construction meets stringent hygienic and corrosion-resistance requirements typical of pharmaceutical, nutraceutical, and biopolymer processing environments.

Key Features

• Coaxial two-fluid nozzle with adjustable vertical positioning for precise雾化 zone alignment—minimizes off-center spray and enhances powder yield uniformity
• Real-time PID-controlled heating system with ±1 °C accuracy across the full 50–200 °C operating range, supporting reproducible process development
• Integrated peristaltic feed pump with continuous flow rate modulation (0–3000 mL/h), enabling scalable feed optimization from 50 mL minimum batch volume
• Dedicated noise-dampening and vibration-isolation architecture for vacuum pump and compressed air supply—reducing operational sound pressure level by ≥15 dB(A)
• Standard 2.0 mm nozzle orifice with optional interchangeable nozzles (0.5, 0.8, 1.0, 1.5 mm) to tune droplet size distribution and final particle characteristics
• Full-color LCD touchscreen interface with intuitive Chinese-language GUI (configurable firmware supports English localization upon request)

Sample Compatibility & Compliance

The YC-2100 is validated for aqueous-based feedstocks only—including protein solutions, enzyme suspensions, polysaccharide dispersions, probiotic cultures, and heat-labile APIs. It is not designed for organic solvents, high-viscosity slurries (>500 cP), or abrasive particulates. The system complies with general mechanical safety standards per ISO 12100 and electrical safety per IEC 61000-6-2/6-4. While not certified for GMP manufacturing, its stainless-steel wetted parts, cleanable nozzle assembly, and traceable temperature control support GLP-aligned process documentation. Vacuum integrity and thermal stability are suitable for pre-formulation studies referenced in USP , ICH Q5C, and ASTM E2937-14 guidelines on lyophilization and spray drying of biologics.

Software & Data Management

The embedded controller logs real-time parameters—including inlet/outlet temperature, vacuum level, feed rate, and heater power—at user-defined intervals (1–60 s). Data export is supported via USB storage in CSV format for offline analysis in MATLAB, JMP, or Excel. Though the base firmware does not include FDA 21 CFR Part 11-compliant audit trails or electronic signatures, the system architecture permits integration with external SCADA platforms (e.g., Ignition, Siemens Desigo) via Modbus RTU over RS-485 for centralized data acquisition and long-term validation compliance.

Applications

• Preclinical formulation of inhalable dry powders (e.g., insulin, heparin analogues) requiring sub-100 µm aerodynamic diameter and residual moisture <1 wt%
• Rapid prototyping of encapsulated probiotics, vaccines, and mRNA-LNPs where lipid integrity and antigenicity must be preserved
• Production of amorphous solid dispersions for BCS Class II drugs using polymer carriers such as HPMC-AS or PVP-VA
• Stabilization of labile natural extracts (e.g., anthocyanins, curcuminoids) without antioxidant additives
• Process parameter mapping (DoE) for scale-up to industrial vacuum spray dryers (e.g., Niro Soavi, Buchi B-90HP)

FAQ

Can the YC-2100 handle organic solvents such as ethanol or acetone?
No. The system is designed exclusively for aqueous solutions. Organic solvent use poses explosion risk under vacuum and exceeds material compatibility limits of standard seals and sensors.
Is the touchscreen interface available in English by default?
The factory-default UI is in simplified Chinese. English language firmware is available upon request and requires re-flashing prior to commissioning.
What is the typical residual moisture content of dried powder produced at 50 °C?
Under optimal vacuum (−0.07 MPa) and airflow conditions, residual moisture ranges from 0.3–0.9 wt%, verified by Karl Fischer titration (ASTM D6304).
Does the system include integrated particle size analysis?
No. The YC-2100 delivers dried powder within the 1–100 µm range but requires external characterization (e.g., laser diffraction per ISO 13320) for distribution profiling.
Can the nozzle be cleaned in place (CIP) without disassembly?
Yes—the coaxial nozzle design allows ultrasonic cleaning in situ using warm deionized water; full disassembly is recommended after every 10–15 batches for inspection and O-ring replacement.