Here are some ideas that may improve YOUR equipment s performance:

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Suzanna Dickerson
5 years ago
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Modernizations & Improvements The bottom line is a processor s profitability. Marriott Walker Corporation recognizes that many processors are using older evaporators and spray driers.

Marriott Walker Corporation prides itself in its willingness to work with processors to modernize and improve their existing evaporators and spray driers when the purchase of new equipment is not in

1 Modernizations & Improvements The bottom line is a processor s profitability. Marriott Walker Corporation recognizes that many processors are using older evaporators and spray driers. Often, the manufacturers of such equipment are long since out of business, leaving processors with few choices in where to turn when their equipment requires modification or improvement. Marriott Walker Corporation prides itself in its willingness to work with processors to modernize and improve their existing evaporators and spray driers when the purchase of new equipment is not in the budget. Many times spray driers can be greatly improved and the production rates of underutilized equipment can be boosted with minimum capital expenditure. Here are some ideas that may improve YOUR equipment s performance: Evaporators Spray Driers Powder Cooling/Conveyors Additional Effects Product Recovery Cyclones Increase Powder Cooling Capacity Shell & Tube Product Heaters Reverse Pulse Baghouses Minimize plugging difficulties Vacuum pumps Wet Scrubbers Maximize production efficiency Shell & Tube Condensers to Indirect Process Air Heaters with the use of powder storage silos replace wet condensers Exhaust Air Heat Recovery Systems Sonic Horns Engineering Surveys Many processors find themselves operating older evaporators and spray driers, for which technical information is sketchy or not available. Evaporators and spray driers have long service lives and many manufacturers of equipment still in operation are long since out of business. Accordingly, many processors find themselves operating equipment for which there is no sophisticated, technical support. We at Marriott Walker Corporation routinely conduct engineering surveys of existing evaporators, spray driers and related equipment, for processors who find themselves in this position. Such surveys often reveal and allow us to quantify equipment problems, difficulties with operating techniques and sometimes discover that the capacity of the equipment is under-utilized. Our engineering surveys include a list of recommendations for the processor s consideration. For engineering surveys and other technical services, contact us by phone, fax, or through our web-site, A graduate of the University of Michigan, the founding father of Marriott Walker Corporation began his career at a Detroit based manufacturer of evaporators and spray driers in He was that firm s first degreed engineer and soon became their Chief Engineer. Marriott invented, and received a U.S. Patent for, the automatic, cable operated, powder-removal sweep system for flat-floor, box-type spray driers, which became an industry standard for decades. As processing requirements and evaporator capacities grew, the increased utility demands called for a more efficient use of steam. Marriott worked closely with thermocompressor A. Marriott Scratch Walker manufacturers and was one of the first to apply thermocompression to multiple effect dairy evaporators, dramatically reducing their steam requirements and increasing their efficiency. Marriott founded Marriott Walker Corporation in 1958, presiding over and leading the company through 43 years of service to the food and dairy industry. Marriott passed away on December 22, In May of 2001, his contributions to the dairy industry were recognized posthumously by the American Dairy Products Institute through the presentation of their prestigious Award of Merit, accepted by his son and current Corporate President, J. Winthrop Walker. It is to the memory of A. Marriott Walker that we dedicate this Corporate Bulletin. MARRIOTT WALKER CORPORATION 925 East Maple Road Birmingham, Michigan USA Ph: (248) Fax: (248) mwc@marriottwalker.com Web: 7

ABOUT MARRIOTT WALKER A leader in the field, Marriott Walker Corporation has been designing and installing evaporators and spray driers for the dairy and food industries

Marriott Walker will not only satisfy the processing needs of your company today but will grow with the demands of tomorrow.

Farms Dairy Wyeth/Ayerst International Land O Lakes Cheese & Protein Int l. Ovotec International A/S Nestle R&D Central Soya Merrick s Inc.

Membrane System Specialists Michigan Milk Producers Association MARRIOTT WALKER EQUIPMENT IS EVERYWHERE Our equipment can be found throughout the United States and in.

the roots of Marriott Walker Corporation are in the dairy industry, our capabilities soon branched out into egg processing, designing equipment for the drying of whole egg,

3 ABOUT MARRIOTT WALKER A leader in the field, Marriott Walker Corporation has been designing and installing evaporators and spray driers for the dairy and food industries since Our proud history of customer loyalty and satisfaction reflects the commitment of Marriott Walker Corporation to design and deliver quality products. Marriott Walker will not only satisfy the processing needs of your company today but will grow with the demands of tomorrow. NAMES WHO KNOW MARRIOTT WALKER Kerry Ingredients Michael Foods Sensient Technologies Canadian Inovatech Albion Labs United Dairymen of Arizona Hilmar Cheese Company Foster Farms Dairy Wyeth/Ayerst International Land O Lakes Cheese & Protein Int l. Ovotec International A/S Nestle R&D Central Soya Merrick s Inc. Sonstegard Foods Dairy Farmers of America California Dairies Wild Flavors Kraft Foods Diehl, Inc. Membrane System Specialists Michigan Milk Producers Association MARRIOTT WALKER EQUIPMENT IS EVERYWHERE Our equipment can be found throughout the United States and in... Australia Ireland Netherlands Canada Wales Germany Puerto Rico Russia South Africa Colombia England Japan Mexico China Venezuela HOW MARRIOTT WALKER CAN SERVE YOU While the roots of Marriott Walker Corporation are in the dairy industry, our capabilities soon branched out into egg processing, designing equipment for the drying of whole egg, yolk and particularly albumen (egg whites). Our ability to process heat sensitive products has allowed Marriott Walker to grow even further, reaching into the production of pharmaceuticals and products such as whey protein, soy derivatives, flavorings, blood, blood plasma, yeasts and other similar products. COVER: Interior of 17 Dia. Spray Chamber 1

Products that Marriott Walker Equipment can Process Egg Products Milk Products Other Products More Products Albumen Skim Milk Infant Formula Animal By-Products Yolk Whole Milk Nutritional Supplements

Protein Concentrate Hydrolized Vegetable Proteins Yeasts Whey Ingredients Nutraceuticals Evaporators Marriott Walker Corporation proudly offers an entire range of custom designed evaporators for food

Several of our pilot plant evaporators have found homes in university pilot plants and in the R&D facilities of major dairy processors.

4 Products that Marriott Walker Equipment can Process Egg Products Milk Products Other Products More Products Albumen Skim Milk Infant Formula Animal By-Products Yolk Whole Milk Nutritional Supplements Coffee Whole egg Buttermilk Ice Cream Mix Coffee Creamers Sweetened Condensed Pharmaceuticals Shortening Milk Minerals Flavorings Soy Protein Isolate Cheese Blood & Blood Plasma Soy Derivatives Whey Protein Concentrate Hydrolized Vegetable Proteins Yeasts Whey Ingredients Nutraceuticals Evaporators Marriott Walker Corporation proudly offers an entire range of custom designed evaporators for food and dairy products, from small pilot plant units through 100,000 Lb/Hr multiple effect systems. Several of our pilot plant evaporators have found homes in university pilot plants and in the R&D facilities of major dairy processors. Our company designs complete evaporation packages, including liquid feed systems, HTST pasteurizers, pre- and post-evaporating heat treatment systems and flash coolers. Production evaporators, in either TVR or MVR configurations, are available in a range of sizes to suit your needs. Vacuum Pans Prior to the development of multiple-effect, continuously operating evaporators, the standard evaporating procedure was to use a batch operated evaporator known as a vacuum pan, in which the product to be condensed is cooked-down under vacuum, within one vessel. A vacuum pan can have internal heating coils, or the product heating can be accomplished in a jacketed vessel. For viscous products, vacuum pans can be provided with swept-surface agitators. Vacuum pans are still the evaporating technique of choice for some jams, jellies and other specialty products. 2

Pilot Plant Evaporators and Spray Driers Marriott Walker Corporation has provided numerous pilot plant evaporators and spray driers for commercial R&D pilot plants as well as

The simplest pilot plant configuration is that of a rising-film, batch type evaporator, in which the evaporator is filled and the product is recirculated under vacuum until the

The more complex variation is a continuously operating falling-film evaporator, which permits a more realistic scale-up from pilot plant to production facilities.

Our tower-type pilot plant spray driers can be provided in a range of sizes and can be designed to use either high-pressure nozzle atomization or two-fluid nozzles.

5 Pilot Plant Evaporators and Spray Driers Marriott Walker Corporation has provided numerous pilot plant evaporators and spray driers for commercial R&D pilot plants as well as university teaching facilities. Our pilot plant evaporators are always custom designed to suit a processor s specific needs. The simplest pilot plant configuration is that of a rising-film, batch type evaporator, in which the evaporator is filled and the product is recirculated under vacuum until the desired solids level is achieved. The vacuum is then broken and the concentrated product is discharged from the evaporator. The more complex variation is a continuously operating falling-film evaporator, which permits a more realistic scale-up from pilot plant to production facilities. If provided with robust vacuum-producing equipment and an adequate condenser, pilot plant evaporators can be designed to operate at temperatures as low as 80 F. Our tower-type pilot plant spray driers can be provided in a range of sizes and can be designed to use either high-pressure nozzle atomization or two-fluid nozzles. Pilot plant driers can be provided with either direct or indirect process air heating and are always designed for easy CIP cleaning and quick turnaround. If your facility would benefit from the flexibility offered by having an in-house pilot plant spray drier, contact the professionals at Marriott Walker Corporation. 3

Spray Driers Marriott Walker Corporation manufactures a full range of spray driers in a variety of configurations.

Our smaller units now see service in pilot plant operations for universities and corporate R&D facilities and our production drier s maximum capacities can be tailored to suit

We offer spray drying systems that include liquid feed and heating equipment as well as powder cooling, sifting, storage and packaging systems.

Single-Stage Tower Driers Marriott Walker Corporation offers custom designed, single-stage tower driers, ranging in size from pilot plant units, through models for full-scale

Product recovery cyclones, baghouses and wet scrubbers can be utilized as circumstances dictate.

Two-Stage Tower Driers Marriott Walker Corporation s two-stage tower drying systems offer increased versatility for difficult to dry products or for processors who need to

As with our single-stage tower driers, variety and adaptability are the keys to our ability to address your processing needs.

6 Spray Driers Marriott Walker Corporation manufactures a full range of spray driers in a variety of configurations. We can provide flat-floor box, V-bottom box and tower driers in a range of custom designed sizes. Our smaller units now see service in pilot plant operations for universities and corporate R&D facilities and our production drier s maximum capacities can be tailored to suit almost any imaginable processing requirement. We offer spray drying systems that include liquid feed and heating equipment as well as powder cooling, sifting, storage and packaging systems. The fact that some of our driers are over 40 years old and still in daily use, is a testimony to their rugged quality and durability. Single-Stage Tower Driers Marriott Walker Corporation offers custom designed, single-stage tower driers, ranging in size from pilot plant units, through models for full-scale production facilities. Our tower driers come in many configurations, depending on your processing requirements. Product recovery cyclones, baghouses and wet scrubbers can be utilized as circumstances dictate. Our largest single-stage tower drier, now in operation, has a water evaporation rate of 18,000 Lb/Hr. Two-Stage Tower Driers Marriott Walker Corporation s two-stage tower drying systems offer increased versatility for difficult to dry products or for processors who need to engage in two-stage drying with agglomerating and powder cooling capabilities. As with our single-stage tower driers, variety and adaptability are the keys to our ability to address your processing needs. Flat-Floor Box Driers V-Bottom Box Driers For many processors, the flat-floor box drier offers an economical and easily serviced spray drying system, without the costly, complex and tall process buildings that tower driers require. For processors that single-stage dry one product or a family of compatible products, the flat-floor box drier is a design worthy of serious consideration. Our largest flat-floor box drier, believed to be the largest in the world, has a water evaporation rate of over 8,500 Lb/Hr. The family of V-bottom box driers, manufactured by Marriott Walker Corporation, is a rugged and vastly improved variation of the traditional V-bottom box drier, well known in the food processing industry. Our family of V-bottom driers was developed in response to processors with modest production needs and are offered in a variety of sizes, up to a maximum water evaporation rate of 1,500 Lb/Hr. 4

Pneumatic Powder Cooling Conveyors Powder Storage Silos and Hoppers Marriott Walker Corporation produces a complete line of sanitary stainless steel powder hoppers and silos, ranging in capacity from

Processors can increase their plant s efficiency and reduce labor costs by utilizing powder storage silos.

Having adequate powder storage capacity allows processors to operate their spray driers around the clock and through weekends, with the labor intensive packaging line operating only one shift, five

Pneumatic powder cooling conveyors serve a dual purpose in that they are designed to cool powders while conveying them from the spray drier s discharge point to downstream processes such as sifting,

7 Pneumatic Powder Cooling Conveyors Powder Storage Silos and Hoppers Marriott Walker Corporation produces a complete line of sanitary stainless steel powder hoppers and silos, ranging in capacity from 500 pound surge hoppers through 350,000 pound, free standing, insulated powder storage silos. These silos are fabricated to USDA and 3-A standards for food and dairy powders. Processors can increase their plant s efficiency and reduce labor costs by utilizing powder storage silos. Modern, high-speed powder packaging equipment can package powders much faster than spray driers can produce them. Having adequate powder storage capacity allows processors to operate their spray driers around the clock and through weekends, with the labor intensive packaging line operating only one shift, five days per week, or less. Pneumatic powder cooling conveyors serve a dual purpose in that they are designed to cool powders while conveying them from the spray drier s discharge point to downstream processes such as sifting, storage, and powder packaging. Most dairy and food powders can easily be cooled utilizing this technique. Even difficult-tohandle powders, such as high-fat coffee creamers and cheese, are successfully cooled in this manner. The technique is simpler, and often less expensive than other powder-cooling means, such as vibratory fluid beds. Pneumatic Powder Transport Conveyors Once the powder produced by a spray drier has been cooled and sifted, it is often desirable to convey the powder to storage silos or to a packaging operation located some distance away from the spray drier. For these duties, the Marriott Walker Corporation can provide complete pneumatic powder transport conveyors adequate to convey up to 30,000 Lbs/Hr of powders over substantial distances. Exhaust Air Heat Recovery Exhaust air heat recovery systems can typically reduce a drier s energy consumption by up to 25%. Heating process air for spray driers consumes a tremendous amount of energy. Significant energy savings can be realized by preheating incoming process air by cooling the exhaust air discharged from the drier. Exhaust air heat recovery systems can be provided in either air-to-air or air-liquid-air designs, depending on the spray drier s design and the processor s needs. 5

8 SPRAY DRIER PERFORMANCE PARAMETERS Performance multipliers can be applied to the standard operating parameters that Marriott Walker Corporation uses in its spray drier design. Our standard operating conditions for spray driers are shown below and they can be used for capacity comparison purposes. 1) Liquid feed solids... 40% 4) Exhaust air temperature F (82 C) 2) Liquid feed temperature F (60 C) 5) Powder moisture... 3% 3) Inlet air temperature F (160 C) 6) Inlet air dew point less than F (19 C) The multipliers can be applied to single-stage spray driers of any configuration, regardless of the manufacturer. The following performance factors may be used as multipliers (or divisors) to determine powder capacities for spray driers running under other conditions. Feed Solids Multipliers: Spray driers are water evaporators and their powder output will vary with the percent of solids in the liquid feed. Table 1, Feed Solid Multipliers, shows multipliers that may be used to determine a drier s powder output at other that 40% solids feed, under constant evaporation conditions. This table applies to powder output only. Do not use it to modify evaporating capacity. Liquid Feed Temperature Multipliers: The temperature of the liquid feed to the spray drier directly influences the drier s evaporating capacity, as shown by the liquid feed temperature multipliers in Table 2. These factors also apply to the drier s powder output. Inlet/Exhaust Temperature Multipliers: Hotter inlet air temperatures and cooler exhaust temperatures will increase the evaporating capacity of the spray drier and visa versa. The difference between these two temperatures measures the capacity of the drier as shown in Table 3, Inlet/Exhaust Temperature Multipliers. This evaporation factor also applies to powder output. TABLE 1: FEED SOLIDS MULTIPLIERS TABLE 2: LIQUID FEED TEMPERATURE MULTIPLIERS FEED TEMPERATURE (F) CAPACITY MULTIPLIER TABLE 3: INLET/EXHAUST TEMPERATURE MULTIPLIERS EXHAUST INLET TEMPERATURES (F) TEMP (F)

Anhydro Spray Drying Plants for the Dairy Industry

Anhydro Spray Drying Plants for the Dairy Industry A Question of Accuracy, Efficiency, and Flexibility Spray drying is a highly cost-effective method of obtaining powder from heat-sensitive liquids such