A number of industrial spray processes involve high-value products for
which even minor deviations in spray quality can quickly result in
significant monetary losses. Examples of such processes include the spray
drying and coating of pharmaceuticals, spray production of high molecular
weight polymer micro beads, spray coating of micro-electronic components,
spray application of barrier coats and resists etc.
spray research provides
qualification of the individual atomizers used in these processes. This
atomizer qualification ensures that the given process will yield
in-tolerance product when the atomizer is changed out for cleaning, periodic
maintenance or replacement.
Our experience in qualifying atomizers used in pharmaceutical spray dryers
and Wurster coaters suggests that less than 50% of the originally
will meet the dimensional tolerances required to maintain rigorous product
quality [view dimensional example]. Of these, approximately 30% will fail to meet the spray performance
standards [view performance example]. Final yields of qualified atomizers for these processes typically
range from 30% to 40%.