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Volume 114
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Effects of injection conditions on the first impact of milk droplets onto the chamber surfaces in the spray drying process (Open Access)
Ali M. Sefidan a *, Mathieu Sellier b, James N. Hewett b
a Department of Energy and Mechanical Engineering, Aalto University, 02150, Espoo, Finland
b Department of Mechanical Engineering, University of Canterbury, Christchurch, 8140, New Zealand
10.1016/j.partic.2026.03.037
Volume 114, July 2026, Pages 36-47
Received 12 February 2025, Revised 12 February 2026, Accepted 26 March 2026, Available online 7 April 2026, Version of Record 12 April 2026.
E-mail: ali.mohammadisefidan@aalto.fi
Highlights

• Numerical modeling of milk droplet impact in spray drying using an Euler-Lagrange approach.

• A four-stage droplet evaporation model was coupled with Euler-Lagrange to track moisture content and temperature evolution.

• Smaller droplets hit the chamber walls at lower impact angles with lower velocity and moisture content.

• Higher injection angles yield smaller impact angles, lower moisture content, and reduced surface temperatures.


Abstract

Through spray drying, a liquid containing solid particles is converted into dry powder by evaporating the solvent. Many industries, such as the dairy industry, use this method to make dry powder as it extends the shelf life of the product and makes it more dense for transport. Milk powder production in dairy plants is highly challenging because partially wet milk droplets can deposit on the surfaces of drying chambers. Through the use of a numerical model, this study examines the effects of injection parameters on droplet conditions at the point of impact with the chamber surfaces during the spray drying process of skim milk. The process was numerically modelled using a four-stage droplet evaporation model coupled with an Euler-Lagrange simulation that describes the trajectory of the milk droplets inside the dryer. According to the results, a greater proportion of smaller droplets impact the wall at smaller angles, with lower velocity magnitudes, and contain less moisture than larger droplets. As a result of a larger injection angle, more droplets hit the chamber surfaces with smaller impact angles, resulting in lower moisture content and lower temperatures at impact. A higher injection velocity resulted in a greater proportion of droplets impacting the surface of the chamber with lower temperatures and a greater moisture content.

Graphical abstract
Keywords
Spray drying; Euler-Lagrange model; Droplet drying model; Droplet impact
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