Spray Dryer Market 2023 – Market Size & Segments Analysis, Industry Trends, Manufacturers Analysis, Opportunities and Forecast 2030

A spray dryer is a device used in various industries to convert liquid or slurry materials into dry powder form. It is commonly used in the food, pharmaceutical, chemical, and dairy industries for the production of powdered products. The spray drying process involves atomizing a liquid feed into small droplets and then exposing these droplets to a stream of hot air. The hot air rapidly evaporates the moisture content in the droplets, forming dry particles.

 

Spray Dryer Market Size

The growing use of spray dryers in a variety of industries is expected to drive the significant expansion of the market in the coming years. In 2022, the size of the global spray dryer market was valued at 5.59 billion USD. It is anticipated to grow at a CAGR of 6.1% from 2023 to 2030, going from USD 5.90 billion in 2023 to USD 8.95 billion in 2030. Because it is used to dry milk powder, coffee, infant formula, and a wide variety of other food ingredients, the food and beverage industry, in particular, has been a major market driver. Pharmaceutical powders, such as inhalable drugs and powdered antibiotics, are made with the help of spray dryers. Europe is the largest and major commercial center for spray dryers because of the presence of key players in the region. The Asia-Pacific region is expected to develop at the absolute best CAGR during the forecast period because of expanding markets and interest in innovation by nations like China, India, and Japan.

Spray Dryer Market Growth Drivers

Spray dryers are widely used in the food industry to convert liquid or slurry food products into dry powders, extending their shelf life, improving stability, and enhancing ease of handling. The pharmaceutical industry relies on spray dryers for the production of pharmaceutical powders, including inhalable drugs, powdered antibiotics, and oral dosage forms offering advantages such as improved bioavailability, controlled particle size distribution, and enhanced drug stability.

The chemical and biotechnology industries utilize spray dryers for the drying of chemical compounds, catalysts, enzymes, and other biotechnological products. The ability of spray dryers to handle a wide range of materials, maintain product purity, and achieve controlled particle size distribution makes them suitable for these industries.

Manufacturers have been focusing on developing more efficient and advanced spray drying systems that offer improved control over drying parameters, enhanced energy efficiency, reduced emissions, and better product quality. They offer advantages such as high production rates, rapid drying times, and the ability to achieve a uniform and consistent powder products ideal for industries aiming to optimize their drying processes.

Spray drying enables the production of powdered ingredients with specific functionalities, such as encapsulation of flavors, vitamins, and bioactive compounds, which can be easily incorporated into various products.

Spray Dryer Market Segmentation

·        By Operating Principle Direct Drying, Indirect Drying

·        By Dryer Type Rotary Atomizer, Fluidized, Nozzle Atomizer, Closed Loop, Centrifugal, Others

·        By Drying Stage Single Stage, Two Stage, Multi-Stage

·        By Mode of Operation Batch Mode, Continuous Mode

·        By Type of Flow Co-Current Flow, Counter Current Flow, Mixed Flow

·        By Capacity Low Capacity (<100 Kg/hr), Medium Capacity (100-1000 Kg/hr), High Capacity (>1000 Kg/hr)

·        By Application Food & Beverage, Pharmaceuticals, Chemical, Others

·        By Region North America, Europe, Asia-Pacific, Latin America, Middle East & Africa

Spray Dryer Market Dryer Type Segment Review

The nozzle atomizer segment held the largest market share of 41.2% of the global market in 2022 owing to the significant adoption of nozzle atomizer-based equipment to produce coarser and free-flowing powders. Moreover, nozzle atomizer dryers can also be used in conjunction with multiple nozzle installations to offer a wide range of flow rates. Rotary atomizer spray dryers use a high-speed rotating disk or wheel to atomize the liquid feed into fine droplets. Fluidized bed spray dryers are widely used in the food, pharmaceutical, and chemical industries for applications such as instantization, agglomeration, and encapsulation. Centrifugal spray dryers are suitable for heat-sensitive materials and high production rates commonly used in industries such as food, pharmaceuticals, chemicals, and ceramics. Other dryers include freeze spray dryers used for freeze-drying applications, hybrid spray dryers that combine multiple drying technologies, and closed-loop spray dryers that integrate spray drying with other drying processes.

Spray Dryer Market Drying Stage Segment Review

The two-stage segment accounted for the largest market share of more than 40.0% in 2022 and is estimated to maintain its dominance in the future attributed to increasing demand for these dryers across various industrial applications owing to lesser production costs without compromising the product quality. Two-stage dryers are usually used by medium- and large-scale industrial manufacturers owing to the benefits offered by this equipment, such as the ability to process varying volumes of feedstock. However, the multi-stage product segment is expected to register the highest CAGR over the forecast period owing to their benefits, such as the ability to control the drop in pressure between the first stage and final stage of the spray drying process instantaneously and to produce dust-free agglomerated products with optimum dispersibility. These benefits would particularly bolster its demand across large-scale food processing industries.

Spray Dryer Market Type of Flow Segment Review

The co-current segment held the largest market share of more than 55.0% in 2022 as the key companies launched a variety of these types of equipment for industrial, laboratory, and R&D applications. Co-current flow dryers are particularly preferred for processing heat-sensitive products owing to their ability to reduce the temperature of the drying air by vaporization of water instantaneously. Mixed flow is expected to be the fastest-growing segment over the forecast period. A mixed flow pattern offers better mixing capabilities and potentially delivers supreme efficiency by combining the co-current and counter-current flow techniques.

Spray Dryer Market Application Segment Review

Food & beverage was the largest application segment in 2022 owing to the significant adoption of the equipment for producing infant products, egg powder, and coffee powder. Moreover, favorable decisions by the governments of emerging economies, such as India and China, to increase the Foreign Direct Investment (FDIs) limits for the food processing industry are encouraging companies of the dairy industry to install processing plants in these countries. Spray drying is used for drug encapsulation, inhalable drug delivery systems, amorphous solid dispersions, protein therapeutics, and other pharmaceutical applications. They find applications in the chemicals industry for producing specialty chemicals, pigments, catalysts, and advanced materials. This technology is also utilized in various other industries, including textiles, paper and pulp, nanotechnology, explosives, and animal feed.

Spray Dryer Market Regional Synopsis

North America accounted for 24.0% of global revenue share i.e., the second largest share of the global spray dryer market due to quick adoption of new and emerging technologies by key companies to improve the overall efficiency and ensure optimum product quality. In addition, higher R&D capabilities across various industries, such as pharmaceutical and nutraceutical, in the U.S.A led to the increased adoption of this equipment. The market is expected to be growing at a CAGR of around 6.4% from 2023 to 2030 with some of the key players in this region including GEA Group AG, SPX FLOW, Inc., Dedert Corporation, Buchi Labortechnik AG, and Advanced Drying Systems.

Europe is the leading market with a global revenue share of around 30.0% of expected to show significant growth at a CAGR of around 5.7% (2023-2030) in the spray dryer market due to the increasing demand for processed food products, pharmaceutical advancements, and expanding applications in industries such as chemicals, ceramics, and polymers. The region has several prominent players such as GEA Group AG, Tetra Pak International S.A, Buchi Labortechnik AG, and European SprayDry Technologies LLP and is expected to witness increased investment in research and development activities with Germany, France, and the UK being the major contributors.

The Asia-Pacific region is expected to show the highest growth rate i.e., a CAGR of 8.1% in the market during the forecast period (2023-2030) fueled by factors such as a large population, rising disposable incomes, changing consumer preferences, and expanding industrial sectors. Moreover, favorable regulations by some of the governments encouraging overseas investors to establish food & dairy production facilities in the region will propel the market.  Some of the key players in this region include GEA Group AG, SPX FLOW, Inc., Dedert Corporation, Buchi Labortechnik AG, Yamato Scientific Co., Ltd., and Tetra Pak International S.A.

The Latin American region is expected to show moderate growth at a CAGR of 6.5% during the forecast period (2023-2030) with Brazil, Chile, and Argentina being the major contributors due to increasing investments in technological advancements and the presence of a large consumer base. Some of the key players in this region include GEA Group AG, SPX FLOW, Inc., Dedert Corporation, Buchi Labortechnik AG, and C.E. Rogers Company.

The Middle East and African region are expected to grow very steadily at a CAGR of 2.5% during the forecast period (2023-2030) with UAE, Israel, Egypt, and South Africa being the major contributors due to rapid industrialization, expanding food processing and pharmaceutical industries, and increasing investments in research and development. Some of the key players in this region include GEA Group AG, Dedert Corporation, Buchi Labortechnik AG, and Yamato Scientific Co., Ltd.

Spray Dryer Market Key Challenges

The spray dryer market is highly competitive, and cost considerations play a crucial role in decision-making such as managing production costs, equipment costs, and raw material expenses while ensuring product quality and customer satisfaction.

Spray drying involves the conversion of liquid or slurry into powder form, which can result in product loss and material handling challenges. It also consumes a significant amount of energy due to the need for hot air generation and handling large volumes of air. Further developing energy proficiency and diminishing energy utilization without compromising item quality is a persevering test in the business.

Spray dryers are complex systems with numerous components, and maintenance requirements can be demanding. Achieving the desired particle size distribution and powder properties is very critical. Controlling the particle size, shape, density, and moisture content of the dried powder can be challenging, particularly when dealing with heat-sensitive or delicate materials.

Scaling up spray drying processes from laboratory or pilot scale to commercial production can be complex. Optimizing the process parameters, including atomization, airflow, and drying temperature, to achieve consistent and efficient production at a larger scale is an enormous challenge that companies face.

VOCs (Volatile Organic Compounds) and fine particulate matter are examples of emissions that can be produced during the spray drying process. Addressing environmental concerns, reducing emissions, and ensuring compliance with environmental regulations are significant challenges for the industry.

Spray Dryer Market Key Global Players

The competitive landscape of the spray dryer market is shaped by several factors, including

·        To remain competitive in the market, ongoing research and development efforts to improve spray drying efficiency, energy savings, and product quality are essential. An advantage accrues to businesses that are able to offer customized solutions, adaptability, and flexibility to satisfy customer requirements, as well as in-depth knowledge and understanding of various industries such as food, pharmaceuticals, chemicals, and ceramics.

·        Customers place a high priority on dependability in terms of equipment performance, durability, and consistency in achieving desired outcomes. Gaining a competitive advantage necessitates providing spray dryers of high quality that comply with industry standards and strict regulatory requirements.

·        Companies that can offer serious valuing without settling on quality and performance enjoy a benefit. Maintaining cost competitiveness necessitates effective management of production costs, operational efficiencies, and supply chain optimization.

·        Customer satisfaction and loyalty are bolstered by prompt assistance, readily available replacement parts, and effective customer service. Companies can stand out from the competition by providing comprehensive after-sales service, technical support, and maintenance services.

Numerous players are vying for market share and investing in new technologies and product development to stay ahead of the curve in the market. Several key global players in the spray dryer market include

·        Acmefil Engineering Systems Pvt. Ltd.

·        Advanced Drying System

·        Buchi Labortechnik AG

·        C.E. Rogers Company

·        Dedert Corporation

·        European Spraydry Technologies

·        Freund-Vector Corporation

·        GEA Group AG

·        Larsson Starch Technology AB

·        New AVM Systech Pvt. Ltd.

·        SPX FLOW, Inc.

·        Swenson Technology, Inc

·        Tetra Pak International S.A.

·        Yamato Scientific Co., Ltd.

·        Others

The organization has been putting vigorously in innovative work to further develop the spray dryer experience and grow its piece of the pie. They have partnerships with several major businesses and significant funding.

The report on the spray dryer market covers the following aspects

·        Market Overview: A general overview of the global spray dryer market, including its current size and growth projections for the future.

·        Market Segmentation: A breakdown of the market by the operating principle, dryer type, drying stage, mode of operation, type of flow, application, and geographic region.

·        Market Dynamics: An analysis of the key drivers, challenges, and trends affecting the growth of the spray dryer market.

·        Competitive Landscape: A comprehensive analysis of the leading players in the spray dryer market, including their market share, product offerings, and key strategies.

·        Regional Analysis: A detailed analysis of the spray dryer market by geographic region, including market size, growth projections, and key trends for each region.

·        Company Profiles: In-depth profiles of key players in the spray dryer market, including their business overview, product offerings, financial performance, and recent developments.

·        Market Forecast: Projections for the future growth of the spray dryer market, including market size, growth rate, and key trends for the next five to ten years.

  

Attributes	Details
Base Year	2022
Trend Period	2020 – 2030
Forecast Period	2023 – 2030
Pages	215
Operating Principle Segment	Direct Drying, Indirect Drying
Dryer Type Segment	Rotary Atomizer, Fluidized Atomizer, Nozzle Atomizer, Closed Loop, Centrifugal, Other
Drying Stage Segment	Single Stage, Two Stage, Multi-Stage
Mode of Operation Segment	Batch Mode, Continuous Mode
Type of Flow Segment	Co-Current Flow, Counter Current Flow, Mixed Flow
Application Segment	Food & Beverage, Pharmaceuticals, Chemical, Others
Company Profiles	Acmefil Engineering Systems Pvt. Ltd., Advanced Drying System, Buchi Labortechnik AG, C.E. Rogers Company, Dedert Corporation, European Spraydry Technologies, Freund-Vector Corporation, and Others
Edition	4th edition
Publication	June 2023