Spray Drying and Atomisation of Formulations

About the course

About the course

This year, due to the Covid pandemic, we will not be running hands-on, face-to-face demos, however throughout the course the theory will be supported by some pre-recorded practical lab demonstrations with some face-to-face discussion around these.

Day 1: Spray Drying and Atomisation Basics: Industry and academic experts provide the essential scientific background.

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.

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.


The 2022 programme will be available shortly, but please find below the programme for September 2021 to give you an idea of content.

This year, due to the Covid pandemic, we will not be running hands-on, face-to-face demos, however throughout the course the theory will be supported by some pre-recorded practical lab demonstrations with some face-to-face discussion around these.

Day One: Tuesday 12 October 2021
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 
  • DEMO 1 (pre-recorded) – feedstock/rheology
  • Atomisation
  • DEMO 2 (pre-recorded) – 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

Day Two: Wednesday 13 October 2021
Industrial Formulation Case Studies

  • Phase changes in spray drying
  • Spray drying with two-fluid nozzles; atomisation, scale-up and modelling
  • Engineering particle structure
  • DEMO 3 (pre-recorded) – single droplet
  • 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
  • Trouble shooting forum/expert consultation session 

Day Three: Thursday 14 October 2021
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
  • Modelling and scale up of spray drying
  • Future directions in atomisation technologies for pharmaceutical applications
  • Online digital modelling, monitoring & control
  • DEMO 4 (pre-recorded) – characterisation of spray dried powders
  • DEMO 5 (pre-recorded) – particle sizing
  • Dryer operation and operational challenges
  • Particle separation; cyclones, filters etc

Course finish time: before 16:30 (exact timings to be confirmed)



2021 course speakers – a list of 2022 course speakers will be available shortly

Course Director:
Professor David York, Visiting Professor, University of Leeds

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

Presenters include:

Dr Sune Klint Andersen, Jannsen Pharmaceuticals 
Professor Andrew Bayly, University of Leeds (formerly of Procter and Gamble)
Dr Arend Dubbelboer, Danone (attending via ZOOM)
Stefan Egan, Procter and Gamble
Henning Falck, Neuhaus Neotec 
Gerrit Fikse, REMBE 
Ian Kemp, Consultant, previously GSK 
Tobias Kockel, Nestlé Switzerland
Dr Joana Pinto, RCPE GmbH 
Deon Pistorius, Dedert
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 (attending via ZOOM)
Dr Daryl Williams, Imperial College London


Fee information


Fees are VAT exempt

Fees include: 

  • cost of tuition

  • course materials

  • lunches

  • light refreshments

Delegates are advised to book early in case any covid-19 restrictions in place at the time of the course result in reduced venue/room capacities and attendee numbers. We will be accepting bookings on a first come first served basis and if we do need to reduce numbers by cancelling bookings delegates will be informed at least four weeks prior to the course and a full refund will be issued.

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 (£6.00 up to twelve hours). 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

Katie Warner – Course Coordinator

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

T: +44 (0)113 343 8104

E: cpd@engineering.leeds.ac.uk

Please note, the CPD team are currently working remotely due to covid-19 and therefore unable to be contacted by phone. If you have any queries please send us an email to the above email address – Many thanks.


This course is supported by iFormulate.

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