Spray Drying and Atomisation of Formulations

About the course

About the course

A practical course involving demonstrations, theory and real industrial case studies.

Day 1: Spray Drying and Atomisation Basics: Industry and academic experts provide the essential scientific background as well as a mix of pre-recorded and practical hands-on laboratory demonstrations.

Day 2: Industrial Formulation Case Studies: Experienced specialists will show how the science of spray drying has been applied to influence the properties of real, formulated products across a wide range of business sectors. Including more laboratory demonstrations.

Day 3: Powder finishing, modelling and future development of spray drying.

During the course you will have an opportunity to highlight problems/individual challenges for discussion with experts in the field.

Expected outcomes
On completion of this course you will:

  • gain an appreciation of how the choice of formulation composition can impact processing and produce quality

  • understand how fluid properties, rheology and atomisation performance can have an influence on spray drying through watching pre-recorded practical lab demonstrations

  • learn how to manipulate drying parameters to influence product microstructure, materials properties and quality parameters

  • gain an appreciation of the hazards involved in spray drying and how to ensure safe operation

  • learn how spray drying processes can be scaled up and appreciate the possible pitfalls on scaling up

  • understand how spray drying principles can be applied to the manufacture of real industrial formulated products for economic and better preforming processes as well as improved product performance and quality

  • find out how spray drying can be used as an alternative to freeze drying

  • get an insight into how challenges are tackled across different industries

  • learn how to choose and design appropriate equipment such as atomisers and towers for laboratory, pilot and production-scale spray-drying.


Who should attend?

This course is suitable for you if you’re:

  • a R&D scientist working in industries such as pharmaceuticals, detergents, foods, agrochemicals or pigments and you’re working in product formulation and need a broad overview of the subject of spray drying and atomisation

  • a scientist or chemical engineer who would value a deeper understanding of how science can be applied to real spray-drying problems

  • a process technologist, plant manager, involved in R&D or a process technician who needs a thorough practical grounding in the subject of spray drying and how it can influence the properties of formulated products

  • A plant or process engineer from contract manufacturer who is seeking process improvements and efficiencies.

  • a university researcher who requires a deeper insight into real industrial problems, unmet needs and potential new research themes.


Please note this is a provisional programme which is subject to change

Throughout the course the theory will be supported by some live and/or pre-recorded practical lab demonstrations as well as an expert led trouble shooting forum*.

Day One: Tuesday 14 June 2022
Spray Drying and Atomisation Basics

Registration: 09:00 – 09:30 

  • Introduction to spray drying, how does it compare with other drying techniques, mechanisms and impact  of the formulation on process and plant design
  • Fluid properties and rheology 
  • Atomisation
  • Drying the particle
  • Modern approaches towards explosion safety in spray dryers
  • Spray drying: basic models, energy balance
  • Scale up of spray drying processes
  • Water in our world, water in our materials
  • Also includes some practical hands-on and/or pre-recorded lab demonstrations

There will be the opportunity to attend a course dinner on Tuesday evening at a city centre restaurant which provides an excellent opportunity to network with other delegates and course speakers, this is offered free of charge to course delegates and we would be delighted for you to attend.

Day Two: Wednesday 15 June 2022
Industrial Formulation Case Studies

  • Phase changes in spray drying
  • Spray drying with two-fluid nozzles; atomisation, scale-up and modelling
  • Engineering particle structure
  • Beyond freeze drying: insights into the development of protein pharmaceuticals via spray-drying
  • Spray Drying an Alternative to Freeze Drying
  • Modelling of the spray drying process using empirical inputs
  • Processing science in an infant milk formulae factory
  • Spray drying for encapsulation and congealing
  • Also includes some practical hands-on and/or pre-recorded lab demonstrations
  • Trouble shooting forum/expert consultation session*

Day Three: Thursday 16 June 2022
Powder finishing, modelling and future developments

  • Agglomeration and build-up in the spray drying tower
  • Managing moisture in practice
  • Product design by fluid bed systems as downstream units of spray dryers
  • Dryer operation and operational challenges
  • Modelling and scale up of spray drying
  • Process Analytical technologies in spray drying
  • Online digital modelling, monitoring & control
  • Dryer operation and operational challenges
  • Particle separation; cyclones, filters etc

Course finish time: 14:20 

*About the Trouble Shooting Forum

This session is one of the most popular and interactive parts of the course. Participants are invited to bring their challenges, questions and problems to a panel of experts. As well as enabling constructive answers to specific queries we also find that the questions are usually interesting enough to lead to a wider discussion of general interest. Some things to remember about the troubleshooting session:
1.    No question is too small (or too big) for the trouble shooting question and questions can be about any topic related to spray drying.
2.    You can send your question or challenge to the panel in advance of the course or ask it on the day.
3.    This year we are trialling an online system to allow participants to ask questions anonymously.
4.    Try to provide some background context with your question. It is a public forum so you should not provide commercially confidential information but we normally find that sensitive details can be anonymised to get around this problem.



2022 course speakers

Course Director:
Professor Andrew Bayly, University of Leeds (formerly of Procter & Gamble)

Course co-Director:
Dr Jim Bullock, Director, iFormulate Ltd

Presenters include:

Dr Sune Klint Andersen, Jannsen Pharmaceuticals 
Dr Ben Douglas, Univerwsity of Leeds
Dr Arend Dubbelboer, Danone 
Henning Falck, Neuhaus Neotec 
Gerrit Fikse, REMBE 
Dr Victor Francia, Heriot Watt University
Dr Karrar Al Dirawi, University of Leeds
Ian Kemp, Consultant, previously GSK 
Joana Pinto, RCPE GmbH
Deon Pistorius, Dedert
Sophie Samain, Nestlé Switzerland
Henrik Schwartzbach, GEA Process Engineering A/S 
Dr David Slade, Applied Materials
George Svonja, Dedert
Professor Phil Threlfall-Holmes, TH Collaborative Innovation & Visiting Professor at the University of Leeds (formerly of AkzoNobel)
Dr Pedro Valente, Hovione 
Filip Van der Gucht, ProCept 
Dr Daryl Williams, Imperial College London
Professor David York, Visiting Professor, University of Leeds


Fee information


Fees are VAT exempt

Fees include: 

  • cost of tuition

  • course materials

  • lunches

  • light refreshments

  • course dinner (Tuesday evening)

View our terms and conditions

Venue details

Faculty of Engineering and Physical Sciences
University of Leeds

Detailed directions (including the exact location for the course registration and presentation room) will be sent out with the delegate joining instructions.

How to find us

The nearest public car park is Woodhouse Lane (multi storey) at LS1 3HQ. The car park is open 24 hours. Charges apply, please click here for information and location details. Please note this car park is a fifteen minute walk to/ from our building and delegates should allow ample time to park and register for the course. 

Car parking for visitors is unavailable at the University.

There is also limited on-street parking in the vicinity of the University.


You’re responsible for your own accommodation, if required. A list of hotels close to the University will be sent with your course joining instructions.

What our delegates say

"An excellent overview of the challenges posed by spray drying" GEA Process

"I gained a good further understanding, excellent mix of people from various industries" Johnson Matthey

"A comprehensive introduction to spray drying for a variety of industrial applications, with deeper dives into a range of topics" Merck Sharp and Dohme

"Very useful to have industrial presenters that can show the "Real World" applications of the theory and advise problem solving questions" Syngenta

Contact us

Jasper Minton–Taylor – Course Coordinator

CPD Conference and Events Unit
Faculty of Engineering and Physical Sciences 
University of Leeds,

T: +44 (0)113 343 5746

E: cpd@engineering.leeds.ac.uk



This course is supported by iFormulate.

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