Spray Drying Facilities
Unmatched with 19 Spray Dryers across 3 strategically located GMP spray drying facilities.
Our three industrial spray drying facilities—in New Jersey, Pennsylvania, and Wisconsin—are designed for flexibility, scalability, and GMP-compliant production. With 19 spray dryers across our network, we offer the built-in capacity and geographic reach to support both pilot runs and high-volume commercialization.
← Back to Spray Drying Services📍 Middlesex, NJ Facility
Our New Jersey facility is part of Spray-Tek’s integrated network of GMP-compliant spray drying sites, providing regional access and built-in redundancy for uninterrupted supply.
- Multiple dryers up to 3000 lbs/hr
- Full range of atomization methods
- Strategic East Coast logistics hub
📍 Bethlehem, PA Facility
Located in Pennsylvania’s Lehigh Valley, this site enhances our tri-state coverage and supports seamless production scalability under GMP conditions.
- Supports pilot to full-scale production
- Diverse spray dryer configurations
- Aligned with BCP and scalability goals
📍 Beloit, WI Facility
Our Wisconsin facility expands national reach and mirrors the capabilities of our other sites—ensuring flexibility, reliability, and speed to market.
- High-volume spray drying capabilities
- Advanced atomization and throughput
- Featured in the aerial video below
Our facilities are strategically designed for high-volume, GMP-compliant production.
Precision Engineering for Maximum Throughputs and Yields
Flexible Capacity to Meet Your Volume and Format Requirements
Our equipment portfolio spans the full range of industrial spray drying demands—from small-scale trials to high-volume commercial production. With multiple dryers across three facilities, we offer a broad range of formats, throughput rates, and atomization options to meet your specific needs.
- Chamber diameters from 6.5 to 14 feet
- Evaporation rates from 15 to 3000 lbs/hr
- Rotary, high-pressure nozzle, and dual nozzle atomization
- Agglomeration capability
- 48 temperature-controlled stainless steel liquid tanks
- 14 tanker-sized bulk storage tanks
Need specific specs or scale-up details? Contact us for a full equipment list.
Analytical Tools for Accuracy, Consistency, and Scale-Up
Every Spray-Tek facility is equipped with advanced analytical instrumentation to support precise process control, product characterization, and quality assurance. These tools help ensure consistent performance across batches and reduce risk during formulation transfer and scale-up.
- Gas Chromatography (GC)
- Malvern Particle Size Analysis
- Karl Fischer Moisture Analysis
- High-Performance Liquid Chromatography (HPLC)
- Scanning Electron Microscopy (SEM)
- Colorimetry
Need a complete list of available methods? Contact us for full details.
Seamless Scale-Up That Bridges R&D and Commercial Production
Our in-house pilot plant is a critical resource for customers looking to transition from development to commercial spray drying. By replicating full-scale production parameters, we help de-risk scale-up, validate formulations, and reduce time to market.
- Pilot dryers engineered to match commercial production conditions
- Supports iterative testing, validation, and tech transfer
- Ideal for new product launches, reformulations, and process refinement
Have a formulation you’re ready to scale? Let’s talk about your pilot plan.
