We use several highly versatile encapsulation processes to prepare particles including atomization processes such as spinning disk, spray drying, spray chilling, and congealing to help solve product performance requirements. Our innovative disk processes yield narrow particle size distributions, produce micron-sized particles, and process batch sizes down to a few grams with high recovery efficiency for consumer products, drug discovery, and more.
We use several atomization processes to solve product performance requirements. Atomization processes include:
- Spinning disk
- Spray drying
- Spray chilling/congealing
Spinning disk is a highly versatile encapsulation process used to prepare matrix morphology and overcoated particles. SwRI staff have innovated the disk process to yield narrow particle size distributions, produce micron-sized particles, and process batch sizes down to a few grams with high recovery efficiency.
Spinning Disk Applications
- Hot melts, prilling, and congealing
- Solvent evaporation
- Water evaporation
- High-solids and high-viscosity feedstocks
Spinning Disk Characteristics
- Particle sizes from 5 µm to 3,000 µm
- Narrow particle size distributions
- Feedstock versatility
- Scalability and high production capacity
- High recovery efficiency
- Continuous production
Spray drying is a traditional atomization process suitable for many feedstocks. Atomization is achieved by nozzle or veined wheels, two-fluid spray nozzles, pressure nozzles, or sonic energy.
Spray Drying Applications
- Water- or solvent-based materials
- Temperature sensitive materials
SwRI scientists use a spray-chilling process to prepare microspheres as shown in the images to the right.