Spray congealing is a continuous process that converts molten materials into uniform granules through rapid cooling. In the oleochemical industry, it’s commonly used to solidify fatty acids like stearic and palmitic acid into stable, free-flowing products.
How Spray Cooler | Beading Plant | Spray Congealing Works
A specially designed spray nozzle is used to atomize molten feed into a cold air chamber. Upon contact with cold air, the droplets lose heat and solidify mid-air, and bead formation takes place. The solidified particles are collected through a fluidized bed cooler to stabilize bead/particle temperature and structure.
Why It’s Ideal for Oleochemicals, Fatty Acids, Waxes, Esters, etc.
Fatty acid processing requires strict control over:
- Granule size distribution (typically in the range of 300–1000 microns)
- Iodine Value (IV) variation (IV range: 1 to 20)
- Minimization of fines and lump formation
- Automation for better operational control and reliability of the plant with the PLC-SCADA system
Spray Cooler/ Beading Plant/ Spray Congealing provides uniformity and flowability, which are critical for packaging, downstream dosing, and thermal stability.
Shachi’s Engineering Approach
Shachi designs Spray Cooler/ Beading Plant/ Spray Congealing plants based on:
- Thermal profile of the specific fatty acid
- Special In-house Nozzle Design for uniform particle size distribution
- Product loading rate considering melting, feed, and required product temperature
- Strict control of feed and product temperature
- Multi-stage cooling for high Iodine Value (IV) Application
- Air Cooling through an evaporative cooler or chiller radiators, based on product requirement
- Plant footprint and layout requirements
- Plant design to operate on open & closed loop configuration
Each plant is complex, customized, and built for easy installation and consistent, long-term, guaranteed performance.
Need a Spray Cooler| Beading Plant| Spray Congealing Setup for Oleochemicals| Fatty Acids?
We build systems mapped to your product’s particle size requirement, High IV feed operations, cooling profile, and flow characteristics.
Talk to our team atshachiengineering.com