Yacheng YC-018 Pilot-Scale Spray Dryer
| Brand | Yacheng / PILOTECH |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Country of Origin | China |
| Model | YC-018 |
| Sample Type | Aqueous solutions only |
| Max Feed Rate | 3000 mL/h |
| Inlet Air Temperature Range | 105–280 °C |
| Particle Size Range | 1–80 µm |
Overview
The Yacheng YC-018 Pilot-Scale Spray Dryer is a benchtop-to-pilot transition instrument engineered for reproducible, scalable powder production via single-stage concurrent spray drying. It operates on the principle of atomizing liquid feed into fine droplets within a heated air stream, enabling rapid solvent evaporation (drying time: 1.0–1.5 s) and formation of free-flowing, spherical particles. Designed for thermal sensitivity preservation, the system limits heat exposure to the transient droplet phase—critical for maintaining bioactivity in enzymes, probiotics, natural extracts, and pharmaceutical actives. Its dual-range inlet temperature control (105–280 °C) supports both low-temperature drying of thermolabile compounds (e.g., glycosides, peptides) and high-temperature processing of refractory materials (e.g., ceramic precursors, metal oxides). The unit bridges the gap between lab-scale discovery and process development, accommodating continuous operation at up to 3 L/h while retaining full parameter traceability and operator safety compliance.
Key Features
- Compact footprint (<1 m² floor space) with ultra-low acoustic emission (<60 dB(A)), meeting ISO 1996-2 laboratory noise requirements.
- Dual-mode control architecture: fully automated PID-regulated operation with manual override capability for method development flexibility.
- High-efficiency cyclonic separation system achieving ≥92% powder recovery—significantly exceeding industry-standard single-cyclone performance—minimizing sample loss during R&D screening.
- Adjustable nozzle assembly with standard 1.5 mm orifice; optional interchangeable nozzles (0.5/0.8/1.0/2.0 mm) enable precise control over droplet size distribution and final particle morphology.
- Integrated needle-cleaning mechanism (‘needle purge’) with programmable frequency prevents nozzle clogging during high-solids or viscous feed processing.
- All-wetted parts—including drying chamber, cyclone collector, and collection tubing—fabricated from electropolished ASTM A276 Type 304 stainless steel for corrosion resistance and cleanability.
- Oil-free compressed air supply ensures particle purity and eliminates hydrocarbon contamination risk—essential for GMP-aligned pharmaceutical and nutraceutical applications.
- Real-time dynamic visualization via 7-inch color LCD touchscreen: displays inlet/outlet air temperatures, blower frequency, peristaltic pump speed, and needle purge cycle status with animated process flow representation.
Sample Compatibility & Compliance
The YC-018 accepts aqueous solutions, suspensions, and emulsions with total solids content ranging from 1% to 30% w/w. It is routinely deployed for drying heat-sensitive biologics (e.g., monoclonal antibody formulations), botanical extracts (e.g., polysaccharide-rich herbal decoctions), food-grade colloids (e.g., whey protein isolates), and inorganic precursors (e.g., sol-gel-derived metal nitrates). The system supports GLP-compliant documentation through timestamped parameter logging and configurable audit trails. While not certified to FDA 21 CFR Part 11 out-of-the-box, its data export functionality (CSV/USB) enables integration into validated electronic lab notebook (ELN) systems. All electrical components comply with IEC 61000-6-3 (EMC) and IEC 61010-1 (safety) standards. Structural design conforms to ISO 22000 hygiene principles for food-contact equipment.
Software & Data Management
The embedded control firmware provides real-time PID regulation with ±1 °C inlet temperature stability. Parameter sets can be saved as named protocols (up to 100 user-defined methods), each storing setpoints for temperature, airflow, feed rate, and needle purge timing. Operational data—including timestamps, sensor readings, and alarm events—are logged continuously to internal memory and exportable via USB to external PCs. No proprietary software installation is required; exported CSV files are compatible with MATLAB, Python pandas, JMP, and Excel for statistical process analysis. Optional RS-485 Modbus RTU interface allows integration into centralized SCADA or MES platforms for multi-unit fleet monitoring.
Applications
- Pharmaceutical: Production of inhalable dry powders (DPIs), amorphous solid dispersions, and excipient-free API microparticles (1–80 µm).
- Food & Nutrition: Encapsulation of probiotics, omega-3 oils, and anthocyanins; production of instant beverage powders with optimized reconstitution properties.
- Materials Science: Synthesis of catalyst supports (e.g., Al₂O₃, SiO₂), battery cathode precursors (e.g., LiCoO₂), and ceramic granules for tape casting.
- Traditional Medicine Research: Stabilization of TCM extracts without Maillard browning or caramelization—enabled by sub-120 °C inlet operation.
- Academic Process Development: Method transfer studies between lab-scale (e.g., Buchi B-290) and pilot-scale (e.g., Niro Mobile Minor) systems using geometrically scaled operating parameters.
FAQ
What is the minimum sample volume required for a valid run?
A minimum of 100 mL feed solution is recommended for stable atomization and representative particle sampling; actual minimum volume depends on solids concentration and viscosity.
Can the YC-018 handle organic solvents?
No—the system is explicitly rated for aqueous-phase feeds only. Organic solvent use poses explosion risk and exceeds design specifications for air handling and material compatibility.
Is the particle size distribution narrow or broad?
The unit produces near-normal PSDs under optimized conditions (CV <25%), with median diameter tunable via nozzle size, feed rate, and inlet temperature—validated by laser diffraction (e.g., Malvern Mastersizer) post-collection.
How is cleaning validation performed?
Electropolished 304 SS surfaces allow visual inspection and swab-based residue testing; SOPs include water-rinse verification followed by conductivity measurement of rinse water to confirm absence of soluble residues.
Does the system support IQ/OQ documentation packages?
Yes—Yacheng provides factory-issued Installation Qualification (IQ) templates and operational test protocols aligned with ASTM E2500 and ISPE GAMP 5 guidelines for user-executed Operational Qualification (OQ).
