Beading Plants
Spray Cooler Manufacturer | Spray Congealing | Prilling Tower
Turn molten oleochemicals into precise, free-flowing beads. Shachi’s beading plant and spray cooling systems convert oleochemicals, castor-oil derivatives, and fatty acids into precise particle size granules. Shachi has been known as one of the most trusted Spray cooler manufacturer in India as well as South east Asia.
Trusted by manufacturers worldwide
Chosen for high-capacity plants by leading food & oleochemical companies, including recent 150 TPD – 240 TPD Beading plant and spray cooling plant installations.
Advantages of Beading Plant
Bead Size
Uniform and custom bead size of 750 um (+/- 150)
Multi-Stage Cooling
from single stage to three stage cooling with integrated fluid bed cooler
Designed for harsh climates (to −25 °C)
Engineered for ambient swings from −25 °C to high-heat, high-humidity
Multiple products
Process-driven operation enables quick changeovers, as well as controlled recycling
Key Features
- Accurate particle size range: typically 300–1000 μm with tight distribution.
- Open/closed-loop operation based on product needs.
- High-efficiency cyclone for fines separation.
- Integrated & external fluidized-bed post-cooling to avoid lumps during production and shipping.
- Specially designed air distributor for even inlet air across the chamber.
- PLC/SCADA-based control with comprehensive instrumentation for reliable, precise operation.
Need technical clarity or a customised solution in evaporation and drying needs?
Beading Plant Applications
Stearic Acid (C18)
Palmitic Acid (C16)
Myristic Acid (C14)
Lauric Acid (C12)
Hard Palm Stearin
Hydrogenated Palm Stearin (HPS)
Glycerol Monostearate (GMS)
12-Hydrogenated Stearic Acid (12HSA)
Hydrogenated Castor Oil (HCO)
Waxes
Esters
Sorbitan Tristearate (STS)
Sorbitan Monostearate (SMS)
Hydrogenated Palm Stearin (HPS)
Glycerol Monostearate (GMS)
12-Hydrogenated Stearic Acid (12HSA)
Recent Project
Need help choosing the right beading solution?
FAQs - Spray Congealing Plant (Beading Plant)
Beading plants atomizes a melt into a cooled air stream to form solid, spherical beads, no solvent, no evaporation. Spray drying removes solvent from a solution/suspension. Spray congealing offers tighter PSD, shorter height, and easier integration.
Oleo chemicals, castor-oil derivatives, fatty acids (C12–C18), waxes, GMS/12-HSA/HCO, esters, and similar melts that remain stable on cooling. If the product can be safely melted and solidified without degradation, it’s usually a good candidate.
Typical target ranges are in the 750 microns (with a range of +/- 150 μm). Particle size distribution (PSD) is tuned via nozzle selection, melt temperature/viscosity control, chamber airflow design, and post-cooling/air classification for fines management.
Energy-efficient fans and drives, balanced airflow, heat recovery on exhaust, insulated ducts/chambers, and closed-loop cooling where needed. Automation (PLC/SCADA) maintains setpoints to avoid over-cooling or rework, reducing energy use, rejects, and downtime.
Open- or closed-loop air systems, single- or multi-nozzle lances, tailored chamber geometry, fluidized-bed post-cooling to prevent agglomeration, cyclone/filters for fines, and hygienic/GMP builds for food & pharma. Systems are modular to match capacity and future upgrades.
Design features include smooth internal surfaces, quick-access doors, warm purge options, and CIP-ready modules for hygienic applications. Changeovers are planned around product melt points and stickiness; with the right design, most line cleans are measured in hours, not days.
Utilities typically include electrical power, chilled water/glycol (or dedicated cooling package), process/clean air, and instrument air. Footprint scales with throughput and cooling duty, from pilot skids (tens of kg/h) to multi-TPH plants. PLC/SCADA integrates with your DCS/MES for recipe control, traceability, and alarms.
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