# Spray Dryer | Multi Effect Evaporator Manufacturer and Supplier - Shachi Engineering > Contact: marketing@shachiengg.com ### Posts #### 1.5 TPH Spray Cooling Plant Commissioned for Global Oleochemical Manufacturer When an existing client returns for a second plant, it speaks volumes about performance, trust, and continuity. After successfully delivering a 2 TPH spray cooling system earlier, Shachi Engineering was once again chosen by a leading Global Oleochemical Manufacturer to commission a new 1.5 TPH Spray Cooling Plant. This plant was designed specifically for the cooling and solidification of GMS (Glycerol Monostearate), —each known for their specific processing challenges. Key Highlights: Capacity: 1.5 TPH Application: Spray cooling and beading of GMS Design: Custom-engineered based on previous plant learnings Status: Successfully commissioned and operational Why Spray Cooling for Oleochemicals? Oleochemicals like GMS require controlled cooling to maintain bead size, shape, and quality. Spray cooling provides uniform particle formation and avoids product degradation—critical for downstream usability. What Made the Difference? Repeat Client Relationship: The same client had earlier commissioned a 2 TPH plant with Shachi, which continues to perform reliably. Material-Specific Design: The plant was tailored to suit the flow characteristics, melting point, and cooling behavior of GMS and fatty acids. Stable Output: The beading process ensures the required particle size distribution and consistent product quality. Commissioning Speed: The project was delivered within the required timeline, thanks to a strong understanding of the process and client expectations. This new 1.5 TPH plant is now running successfully, quietly supporting production needs while maintaining operational consistency. #### 3 Key Selection Parameters for Mechanical Vapor Recompression(MVR) in self-cleaning evaporators Webinar | 3 Key Selection Parameters for Mechanical Vapor Recompression(MVR) in self-cleaning evaporators| 30th October 2020 | 2.00 noon to 3.30 noon Save up to 41% energy in evaporators for effluent waste water treatment Self-cleaning technology has enabled the availability and reliability of evaporators by significantly eliminating fouling. Developed by the Netherlands based Klaren International BV, the technology is now successfully used in India with Shachi Engineering. The technology eliminates fouling and helps process plants to save on cleaning costs and also the downtime required for cleaning and maintenance. However, the benefits of self-cleaning technology do not end here. With Mechanical vapor recompression, you could save 41% of the primary energy used in self-cleaning process. MVR involves adding a compressor to the self-cleaning evaporators. The vapor coming from the evaporator is then compressed to increase its pressure and temperature, and can be used in the shell side of the heat exchanger where it condenses. Thus, the energy used in evaporating the latent heat is recovered and the dependence on primary energy is significantly reduced. When applying self-cleaning process to a multi-effect evaporator, you must choose the effect which generates the most amount of fouling. When this is done, the fouling in that one effect is eliminated, but it remains in other effects, even though its significance is considerably reduced. Mechanical vapor recompression also eliminates this problem. The present white paper discusses the precise benefits of adding MVR to self-cleaning technology. The working of self-cleaning technology The operating principle of the self-cleaning fluidized bed heat exchangers is based on the circulation of solid cleaning particles through the tubes of a vertical shell and tube heat exchanger. The fouling liquid flows upward through the tube bundle of the heat exchanger which incorporates specially designed inlet and outlet channels. Solid particles are fed to the fluid through the inlet channel. A proprietary distribution system is employed to ensure a uniform division of particles over all the tubes. The particles (mostly stainless steel or ceramic particles with a size between 1 and 4 mm) are fluidized by the upward flow of liquid, where they create the mild scouring effect on the wall of the heat exchanger tubes, thereby removing any deposit at an early stage of fouling formation. After the tube bundle the particles disengage from the liquid in the separator and are returned to the inlet channel through an external down comer, and the cycle is repeated. To control the amount of particles fed to the inlet, a part of the inlet flow to the heat exchanger is used to push the particles from the down comer into the inlet channel. With the self-cleaning heat exchanger many types of fouling deposits can be effectively handled, whether hard or soft, originating from biological, crystallization, chemical or particulate fouling mechanism, or a combination of all these types. A comparison of MVR and MEE Energy efficiency As stated before, the MVR requires significantly less energy than a MEE. For the latter, the energy consumption in the form of fresh steam is highly dependent on the use of a thermo compressor (TVR), the selection of the entrainment ratio when applying a TVR, the number of effects in the MEE and the configuration of the pre-heater train. For a 4- effect MEE with TVR and an entrainment ratio of 1, a steam consumption of 0.28 kg steam per kg of water evaporation is quite a representative number. Besides the consumption of steam, the MEE-plant with condenser will also use electricity. The electricity consumption is about 0.03 kWh per kg of water evaporation. When using a boiler plant efficiency of 75 % and an efficiency for a conventional power plant of 33%, it can be calculated that it takes 73 kg of coal to evaporate 1 m3 of water when using a MEE. Energy use of MVR and MEE * per kg water evaporated ** per m3 of water evaporation A typical MVR with a double stage compressor takes 0.06 kWh to evaporate 1 kg of water. When we assume the same power plant efficiency of 33% to produce electricity, we can calculate that it takes only 43 kg of coal to evaporate 1 m3 of water when using a MVR. So, ultimately, one can save 41 % in the use of primary energy when using a MVR to treat waste water by concentrating it through evaporation. Case study: Self-cleaning in dye-stuff effluent treatment The effluent from a dye-stuff manufacturer is characterized by a combination of salts and organic compounds. When concentrating this effluent, the liquid develops a thick and hard deposit on the hottest tube wall which is that of the first effect. Experience has shown that within 250 to 300 hours the evaporation capacity of a 4- effect evaporator is reduced by 50%. After retrofitting the first effect with the self-cleaning fluidized bed technology, the evaporation capacity remains constant over time. In this typical case, the fouling in the second, third and fourth effect was less significant than that in the first effect, but it had reduced after the retrofit as well. Knowing the strong dependency on the exact liquid composition, the performance for a second evaporator plant of the same client but at a different site with a different effluent composition showed that introducing the self-cleaning technology solved the fouling in the first effect but the other effects still had fouling. Therefore, the evaporation capacity still reduced over time but at a much smaller rate increasing the average capacity and the time between cleanings. Evaporation rate MEE plant before and after the revamp of the 1st effect to self-cleaning The design of an MVR system depends on two factors: The compressor used in the process and the composition of the liquid being processed. Compressor performance The thermal design of a MVR requires careful attention with respect to the compressor performance, the composition of the liquid and the required heat transfer area. The compressor design and selection determines the temperature increase delivered to the vapor and yields the driving force for heat transfer between the condensing vapor and the liquid at the tube side. The higher the temperature difference, the lower the required heat transfer area (HTA). On the other hand, the higher the temperature increase the more power the compressor will consume. Liquid composition The required temperature increase will also depend on the liquid composition because specifically salts increase the boiling point of the liquid. This boiling point elevation (BPE) is lowering the temperature difference between vapor and shell. For example, if the vapor from an atmospheric evaporating system is 100o C, the liquid will boil at 108o C when assuming a BPE of 8o C. When the two-stage compressor gives a temperature increase of 16o C, the vapor will condense at 116o C. The driving force for heat transfer then roughly becomes 8 degrees. In case of a single stage compressor with temperature increase of only 8 degrees, no driving force would be left. The required heat transfer will linearly depend on the temperature difference after correction for BPE. When the BPE is under-predicted, the chosen HTA could become too small affecting the capacity by only tens of percentage points. Since fouling can easily reduce the coefficient of transfer by 50% or more, the formation of scales can just as well have a detrimental effect on the evaporation capacity. Self-cleaning system prevents overdesign and keeps the plant capacity constant. Factors to consider when adding the compressors Operating compressors will require some attention of plant operation. When using root blowers, the equipment is more robust and needs less attention then turbofans. Turbofans have fast running impellers with high tip speed that are susceptible to vibration when the impellers get dirty. Monitoring the vibration and stopping the fan in time will prevent larger damages. When taking care of the compressor, experience has shown that MVR units have a good reliability. Conclusion So, to conclude, the self-cleaning evaporator using a MVR is the way to go as to save on primary energy when treating effluent and maximizing the potential of the self-cleaning heat exchanger technology. Get in touch to know more #### 30 KLD MVR-Based ZLD Plant Commissioned for Stainless Steel Manufacturer When a large stainless steel manufacturer in India planned a plant expansion, wastewater treatment was one of the first priorities. The space was limited. The effluent was complex. The timeline was tight. And the solution needed to work every day, without fuss. That’s where Shachi stepped in. What was needed The requirement was clear:A 30 KLD Zero Liquid Discharge (ZLD) plant that could handle both RO reject and spent acid streams, within a compact layout, while staying cost-effective in the long run. The client was looking for: A plant that fits within space constraints Proven technology suited for steel industry effluents Reliable and consistent operations Lower operational costs compared to traditional MEE systems How it was built The ZLD plant was designed around an MVR-based evaporation system, equipped with a horizontal Calandria forced circulation evaporator and supported by a German-made MVR blower for consistent and reliable performance. Key features included: Compact footprint: 30% smaller than conventional setups Energy-efficient operation: 50% lower OPEX Dual stream handling: Designed to process RO reject and spent acid, individually or in combination Reliable components: MVR blower sourced from Germany for long-term stability Smooth compliance: The system meets regulatory norms for reliable operations The plant was engineered, supplied, and commissioned as a turnkey project. The ZLD plant is now up and running, processing complex wastewater streams with ease. It’s a reminder that when the design is right, performance doesn’t have to come at the cost of space, complexity, or sustainability. Looking to design a ZLD system around your plant, not the other way around? Talk to the team at marketing@shachiengg.com #### 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements, nutrition powders, protein blends, herbal extracts, and health drink ingredients. Spray drying helps convert liquid formulations into powders or granules that are easier to handle, mix, pack, and consume. A Spray Dryer for Nutraceuticals must protect product value, support production flexibility, and deliver consistent powder quality. 5 Challenges in Spray Drying for Nutraceuticals 1. Expensive Ingredients Must Not Be Lost Nutraceutical ingredients are often costly. Poor powder recovery, product sticking, or inefficient collection can directly reduce margins. The spray dryer must support the highest recovery. 2. Heat-Sensitive Actives Must Retain Their Value Many nutraceutical ingredients can lose their desired properties when exposed to excess heat. The drying process must be gentle enough to protect nutritional value, colour, taste, and functionality. This is where controlled temperature profiles and multistage drying become important. 3. Hygroscopic Powders Must Stay Stable Many nutraceutical powders absorb moisture from the air. This can lead to stickiness, lump formation, poor flowability, and reduced shelf life. Proper process air control, humidification, cooling, post-drying, and post-cooling help maintain powder stability. 4. Encapsulation Must Improve Product Performance Some active ingredients need protection during processing and storage. Encapsulation helps improve stability, solubility, dispersibility, and bioavailability. With the right drying approach, powders and granules can be designed for better performance in the final formulation. 5. Process Control Must Support Product Flexibility Every nutraceutical product behaves differently. Atomiser RPM, pressure, feed rate, airflow, and temperature must be adjusted as per the product. A well-designed system gives manufacturers the flexibility to handle different formulations, powder properties, and production needs. Shachi is the No. 1 Partner for several nutraceutical manufacturers in India to design their Spray Dryer Plants. We have worked closely with owner managed businesses as well as large corporations, from understanding requirements to successful commissioning. Plants designed by Shachi are very successful with demonstrated performance in final quality requirements. Shachi’s plants have delivered on every parameter as expected – product quality to profitability, and continue to be the competitive edge of the clients #### 5 Things to do at Dahej Industrial Expo 2023 Dahej, with its industrial significance and coastal location, plays a crucial role in Gujarat’s economic development. While primarily known for its industrial estates and petrochemical complexes, its industrial Expo remains the year’s highlight for all the industrialists! Dahej Industrial Expo has been one of the largest B2B expos in Dahej for the last two years. Exhibitors from diverse industries, including chemical, petrochemical, pharmaceutical, engineering, and manufacturing, participate to showcase their products. The Expo has a lot to offer for visitors, and here are five things you can do while you’re there. 1. Visit Shachi Engineering’s Booth Shachi has been participating in the Expo since its inception. This is our third year, and we are excited to showcase our advanced range of products. From Zero Liquid Discharge Plants to Spray Dryers, we have everything in store for you. Explore the progressive advances in cooling, drying, and evaporation technologies and learn more about the sustainable solutions that Shachi can customize to meet your needs. Meet us at Booth – 97, Hall B, from 5th-7th December. 2. Talk To Our Experts Our experts are the backbone of Shachi Engineering. Take this opportunity to engage in meaningful discussions, gain valuable insights, explore potential solutions for your challenges, and have a heartfelt laugh. Whether you’re interested in process optimization, technology integration, or sustainability initiatives, our experts are equipped to guide you towards innovative and efficient solutions. 3. Discover Shachi Engineering’s Unit 2 Shachi has recently opened a new facility in Bharuch, which has doubled its manufacturing capacity. With the new Unit in Gujarat, it is now more accessible for industrialists to visit and gain knowledge about our products. This expansion allows for exploring the latest technological advancements, increased production capacities, and enhanced capabilities. At Shachi, we are always at the forefront of meeting the evolving needs of our clients. Now, you can experience this for yourself at our new second Unit. 4. A Tour Of Shachi’s Unit 2 Factory Beyond the confines of the Booth, we extend an exclusive invitation to take a guided tour of our factory. During the tour, you will witness the precision and dedication that go into every aspect of our manufacturing processes. From conceptualization to production, experience the journey of transforming ideas into reality. Our on-request factory tours offer a unique opportunity to understand the intricate workings of Shachi Engineering and the quality that defines our products. 5. A Walk On The Sandy Beach After all the insightful discussions and stall visits, take a break to chill and relax. Explore the beautiful coastline of Dahej and take a leisurely walk on the Beach to calm your mind while experiencing the serene sound of waves during sunset. Don’t forget to eat the famous Jalebi-Fafda and end your visit to the Dahej Industrial Expo on a sweeter note! Shachi Engineering Invites You As the Dahej Industrial Expo 2023 commences on 5th December, Shachi Engineering invites you to Booth 97, Hall B, for an immersive experience. Engage with our experts, discover more about our second Unit, and let’s explore how Shachi can be the solution to your challenges. Step into a world of possibilities—join us at the Expo, and let’s create a vision for success together! #### A Global Success – Shachi was chosen to deliver Spray Cooler Plants with 1.5 & 2 TPH capacity by one of the world’s largest food companies. Client’s Product GMS (Glycerol monostearate), Stearic Acid & Palmitic Acid Timeline 5 months Plant Capacity Plant 1 – 1.5 TPH Plant 2 –  2 TPH Project Status Commissioned & Handed Over Shachi’s Technology and Equipment Spray Cooler Plant | 3 Stage Cooling and Product Recovery Project Snapshot Shachi played a vital role in establishing a Spray Cooler Plant for a prominent international food (oleo chemicals, edible oils and fatty acids) company. The project aimed to meet the needs of their new Glycerol Monostearate (GMS), Stearic acid and Palmitic acid plant by delivering two Spray Cooler Plants with capacities of 1.5 TPH and 2 TPH, respectively. The cooler’s nozzle design enabled the production of two different particle sizes, which proved to be beneficial for the client. About the client   The client is one of the largest food companies in the world. Over the years, this company has grown from a small workshop to the oil and fat industry leader. Challenges Provide a turnkey solution for the spray cooler plants. Ensure particle size distribution. Strict requirements for plant capacity. Mechanism to avoid product lump formation. Design the plants at a 30-meter height due to space constraints. Solutions Technical Prowess in Spray Cooler Plant DesignShachi leveraged its technical know-how to design and build efficient Spray Cooler Plants, ensuring they met the client’s strict capacity and product quality requirements. Rich Experience in Spray Cooler Plant ProjectsWith a history of successful Spray Cooler Plant projects, Shachi’s experienced team navigated project complexities seamlessly, adapting technology to the GMS, Stearic acid and Palmitic acid plant’s unique needs. Advanced Manufacturing FacilityShachi’s cutting-edge manufacturing facility enabled precision engineering and production, ensuring components met quality standards and project timelines. This infrastructure was pivotal to the project’s success. Airflow PatternsDeveloped a unique Air Distributer with an innovative design that achieves distinctive airflow patterns Removal of heat of crystallization in productUse of External Vibratory Fluidized Bed Cooler for post-cooling to avoid lump formation. Shachi overcame these challenges by leveraging its technical expertise, vast experience, and state-of-the-art manufacturing facility. #### Advantages of Computational Fluid Dynamics (CFD) When life is surrounded by uncertainty and the stakes are high, a fortune-teller who could accurately predict the future for us would be of great help. CFD system does something similar for the sensitive business that is spray drying. Running a computer simulation of how drying process will affect fluids and other factors gives the engineers insights into how the product will perform without having to run tests with actual material. In this blog, we will look at some of the major advantages of Computational Fluid Dynamics Advantages of CFD Relatively low cost A CFD simulation is performed using a computer and does not require heavy scientific equipment and accessories used in conventional methods. CFD simulation is therefore an inexpensive process. Faster speed of analysis As CFD simulations are executed on computers execution and can be completed in much shorter durations. Higher computation power can further reduce the time required for analysis thereby permitting greater scope to experiment and improve the results. Ability to predict the real condition With CFD, actual process conditions can be accurately predicted even in case of irregular geometry and complicated physics. Comprehensive and detailed information CFD analysis allows to assess every possible information associated with physics of the problem situation. As a result, very minute detailing can be predicted and gathered for taking better decisions. The global market for CFD technology is projected to grow at 11% between 2019-24. Efforts are curently on to apply artificial intelligence in developing computational mesh, which is one of the most time-consuming processes in CFD. Get in touch to know more #### Ana Plant Commissioned Shachi Engineering, in collaboration with Taprogge-Klaren, is proud to announce the successful commissioning of its first Zero Liquid Discharge (ZLD) Plant in the oleochemical industry. This state-of-the-art ZLD plant, with a feed capacity of 52 KLD, features a Three Effect Forced Circulation Evaporator followed by an Agitated Thin Film Dryer (ATFD). What sets this plant apart from conventional evaporator systems is the integration of backward feed technology and the implementation of Klaren’s advanced self-cleaning technology in the first effect. These innovations are specifically designed to address the effluent feed’s high scaling tendencies, which typically pose significant challenges in traditional evaporators. In conventional systems, chemical Clean-in-Place (CIP) methods often fail to effectively manage scaling in the calandria tubes, leading to frequent downtime, reduced plant capacity, and increased operational costs. In severe cases, the scaling becomes so extensive that even chemical CIP is insufficient, necessitating the use of high-pressure hydro-jetting—a laborious, time-consuming, and potentially unsafe procedure. To overcome these issues, our newly commissioned plant incorporates Klaren’s cutting-edge self-cleaning technology, which enables continuous operation without the need for plant stoppages. This system can achieve higher concentration levels than conventional evaporators, significantly improving overall efficiency while reducing downtime and maintenance costs. This pioneering approach marks a significant milestone in the oleochemical industry. It allows for extended operational periods and delivers unparalleled performance. #### Celebrated our 23rd Foundation Day Anniversary On 14th July 2021, Shachi Engineering celebrated its 23rd Foundation Day Anniversary. In our 23 years’ journey, we completed 350+ projects and served over 250+ esteem clients across the globe. During the event, our Managing Director, Mr. Marthu Shanbhag unveiled the future plans and roadmap for the company. He also emphasized on following the company values every day. At Shachi Engineering, we are excited about the future growth and our commitment to provide efficient, reliable and sustainable solutions to the customers. We extend our heartfelt gratitude to everyone who has been a part of the Shachi Engineering’s journey over the years, including customers, vendors, employees and other stakeholders. #### Celebrating 27 years of Shachi Engineering A Journey That Started with Clarity and Commitment In 1998, Shachi Engineering was founded on a simple idea: to solve real industrial problems through practical, performance-driven systems. The first few years were all about listening to the client, refining every delivery, and making sure every machine installed made a difference. What we didn’t have in size, we made up for in intent. The process industry trusted us because we stayed close to the work and took ownership of every project as if it were our own. Step by Step, Capability by Capability As our clients’ needs evolved, so did we. What began with drying systems soon grew into evaporation technologies, spray congealing plants, and zero liquid discharge setups. Every addition to our offering came from experience, designed and developed by teams who had been on the shop floor, handled the challenges, and seen what works in practice. Over time, the growth took shape: 500+ projects 400+ clients 10+ countries 2 manufacturing facilities 2 business units 4 international tie-ups These numbers reflect scale, but behind each one is a team, a relationship, and a learning curve we’re proud of. Foundation Day 2025: A Day That Felt Like Us On 14th July, we celebrated Shachi’s 27th Foundation Day. It wasn’t a corporate show. It was a day that truly felt like who we are: grounded, energetic, and people-first. The morning began with a traditional pooja and deep prajwalan, setting the tone with positivity and reflection. From there, the mood shifted into full-on fun with activities like musical chairs, tug of war, and group games that brought everyone together, from interns to senior leadership. A Celebration That Went Beyond Us One of the most meaningful parts of the day was spent with a group of specially-abled children who joined us for the celebrations. There were shared meals, thoughtful gifts, and playful activities planned just for them. It wasn’t about doing something different. It was about staying connected to what matters  people, joy, and community. The Road Ahead As we move ahead, our focus stays on strengthening what we’re known for. We’re investing in R&D not just for the sake of innovation, but to make our systems work better on the ground. We’re working on making our spray dryers more energy-efficient, improving the consistency and control in our spray cooling and beading plants, and optimising our ZLD systems for better recovery and lower running costs. We’re also upgrading automation across plants to give clients more control, better monitoring, and easier maintenance. The goal is simple: to continually improve what we build, based on real feedback and genuine needs. A Note of Gratitude 27 years in, and it still feels like we’re just getting started. To every person who’s been part of this journey, thank you. This Foundation Day was a celebration of what we’ve built, but more importantly, who we’ve built it with. #### Celebrating Phenomenal Growth and Success! Over the past half-year, Shachi Engineering has achieved remarkable success through a focus on innovation and customer satisfaction. Our journey is a testament to our dedication and hard work. Let’s take a closer look at our journey. Innovative Solutions for Customers At Shachi Engineering, we are committed to evolving and adapting to meet our customers’ diverse needs. Our products incorporate sustainable and forward-thinking technologies, allowing our clients to achieve outstanding results. We specialize in Dryers, Evaporators, Spray Coolers, ZLD Plants, and ATFD, providing comprehensive solutions for our clients and inquiries. This dedication to innovation has been a driving force behind our growth. Expanding Globally Shachi Engineering is reaching new horizons. We’re now expanding our global presence to markets in Africa, Southeast Asia, and beyond. With a presence in over 10 countries, we’ve completed more than 350 projects and have served over 225 clients. Our commitment to quality and excellence resonates with a global audience, making us significant internationally. Teamwork is Dreamwork! Behind our achievements is the hard work and teamwork of our dedicated professionals. We wholeheartedly appreciate their dedication and efforts, which have been instrumental throughout these years. Progressing, Proceeding, Prospering As we celebrate our success, we eagerly anticipate the future and the infinite opportunities it brings. Our commitment to innovation, excellence, and customer satisfaction remains unwavering. Together, we’ll continue to grow and set new industry standards, delivering exceptional value to our clients. We always look forward to adding many more exceptional chapters to the Shachi Engineering story. #### Commissioned: 5TPH Beading Plant for Multiple Fatty Acids in Indonesia Client: A leading FMCG manufacturer, Indonesia Application: Lauric Acid (C12), Myristic Acid (C14), Palmitic Acid (C16), Stearic Acid (C18) Capacity: 5 TPH Location: Medan, Indonesia Project Scope: Design, Engineering, Supply, and Commissioning of a Spray Cooling–Beading Plant The Real Challenge The client approached Shachi Engineering with a clear but complex requirementOne beading plant that could handle four different fatty acids efficiently.Each acid has its own flow behavior, melting point, iodine value (IV), and cooling characteristics. The risk? A one-size-fits-all setup could compromise product quality, stability, or performance. The core concern was switching between products without losing efficiency or consistency. Shachi’s Approach Instead of treating this as just another beading system, Shachi considered it a materials problem with an engineering answer. The goal was to build a plant that adapts not struggles across all four applications. Here’s how it was done: 1. Open & Closed Loop FlexibilityBased on the product’s cooling behaviour and environmental factors, the plant was designed to run in both open and closed loop modes. 2. Iodine Value Range HandlingThe system was made compatible with an IV range of 1 to 20, so that low as well as high IV products can be operated in a single plant. 3. Removal of Heat of CrystallizationAn External Vibratory Fluidized Bed (VFB) Cooler was integrated to efficiently remove the heat of crystallization after the bead formation so that lump formation of the beads can be avoided. 4. Fine Separation & Clean DischargeA high-efficiency cyclone separator captured fines, and clean air was exhausted to the atmosphere or recycled back to the system during closed-loop operation. 5. Uniform Air Flow DistributionUniform air flow was engineered throughout the spray chamber with specially designed air distribution to avoid irregular bead formation, which is especially critical when switching between multiple products of different melting point. 6. Automation with PLC-SCADAA fully automated control system gave the plant operators visibility, control, and repeatability minimizing manual errors and ensuring smooth changeovers. The Outcome The 5TPH plant is now commissioned and operational, running smoothly across all four fatty acid applications. Changeovers are efficient Product quality is consistent Energy use is optimized Operational control is seamless What started as one challenge became an opportunity to build a solution that was adaptable, efficient, and easy to run everything the client needed. Looking for a beading plant that runs for multiple fatty acids applications? Let’s build one that works for your plant, materials, and teams.Reach out to us at https://www.shachiengineering.com/ #### Creating better profitability in the extremely competitive Dyes market Spectrum - A market leader in Disperse Dyes Spectrum is one of the largest producers of Disperse Dyes in India. Having started its operation in the year 1991, Spectrum’s wide inventory of over 150 dyes, places it amongst one of the very few manufacturers catering to almost all commercially available Disperse Dyes. Until now Shachi Engineering has successfully installed seven process plants for Spectrum. Challenge The Price Sensitivity Dyes is a highly price sensitive product and the competition, especially from Chinese imports, is very intense. Ensuring very high fuel efficiency, low maintenance and achieving the targeted output is key to profitability. Fuel Economy Challenge Spectrum’s management team had set an aggressive target for fuel economy and plant output. The plant had to reduce its emissions in the form of fog or smoke though the scrubbing system to meet all the stringent emission control norms specified by the pollution control board. Solutions Shachi Engineering responded to the challenges and constraints specified by Spectrum with several innovations: The Gas Burner was designed to yield better combustion efficiency A specialised tall Chamber with better residence time was designed to ensure highest output and positive impact on fuel economy The air distributor was designed by Shachi Engineering to specifically serve the application goals A high-efficiency cyclone system ensures minimal material wastage. The Scrubber designed by Shachi Engineering ensured pollution well within the permissible norms for all types of dyes including those (such as yellow, red or blue colour dyes) that are considered to be difficult to process and cause higher levels of pollution. Results Excellent results for the Client in the form of the best fuel economy 100% throughput as per the target Emission levels well within the pollution control norms This ensured that the Client was not just able to produce good-quality product but do so at a very healthy profitability for years together. #### Creating the Feed to Future with Colourtex An aggressive company with futuristic goals.. Colourtex is a market leader in India for dyes and dye intermediate. The company has been growing at an astonishing pace over the last decade, and has been leading the way through automation and innovations in process engineering. Shachi Engineering has been associated with Colourtex for over two decades and has supplied over 35 Plants for applications ranging from dye intermediates to effluent treatment. In its long association, Shachi Engineering has also upgraded Colourtex’s existing plants to solve problems in through-put, productivity and fuel consumption. Colourtex growth plans are aggressive. So are its expectations when it comes to the performance of the plants. The Management’s outlook has always been futuristic and therefore highly demanding all across, whether it the quality of production or the functioning of the plants. Together, Shachi Engineering and Colourtex’s teams have set several new benchmarks in the Dye manufacturing industry. Challenge For the new expansion project planned, Colourtex wanted to set-up a high capacity Zero Liquid Discharge Plant. The ZLD equipment used were Evaporators and Spray Dryer for this project. Frequent Cleaning The key challenge in using Evaporators is the frequent cleaning required due to fouling to keep the plant operational. Cleaning of Evaporators requires to stop the production. Shutting Down Time The losses incurred by Colourtex in shutting down the plant frequently like loss of production time, which is extremely valuable in a price competitive market such as Dyes, made it economically non-viable option in this case. Solutions Shachi Engineering provided an innovative solution which included a Spray Dyers and Evaporator that functioned as the ZLD plant. Further, Shachi Engineering used a self-cleaning evaporator technology in collaboration with Klaren, Netherlands. The new evaporators meant the Colourtex had to clean the evaporator plant once in a few months as opposed to once every week. The ZLD plant was recognised by Colourtex as one of the best engineered plants and was complete with instrumentation and automation including PLC, SCADA systems. Results Colourtex was able to achieve significant savings with Improved productivity and Higher throughput Labor and cost savings achieved from far lesser shutdowns Output achieved as per the commitment at proposal stage Shachi Engineering has set yet another benchmark with Colourtex with a well proven design, successful installation and the desired performance of the self-cleaning evaporator technology. An interest from several other manufacturers for this futuristic Plant has been the best testimony to the innovations and success of Shachi Engineering. #### Eliminate Evaporator Fouling with the Self Cleaning Technology Webinar | Eliminate Evaporator fouling with the innovative self-cleaning technology | 31st July 2020 | 11.30 am to 12.30 noon The story of India’s first Evaporator working without a shutdown for years and yet providing constant evaporation capacity Why Attend? Fouling of evaporators is unavoidable when used in treatment of effluent waste water. Fouling can reduce evaporation capacities of evaporators by up to 70% within just a few months of operations. Fouling also reduces efficiency and leads to high maintenance costs in evaporators. The only solution to this, until now, has been to clean the evaporators every few weeks or to keep a redundant capacity. Both are very costly options. In this Webinar Marco van Beek, Chief Technology Officer, Klaren International – Netherlands will share how the self-cleaning fluidised bed Evaporator technology adopted and implemented by Shachi Engineering in India is helping to achieve constant evaporation capacity by eliminating fouling. Case Study and Analysis: One of India’s largest chemical dyes manufacture Marco and the team from Shachi Engineering will share the analysis of the first self-cleaning Evaporator plant installed in Gujarat – India. 3 ways to reduce costs and get better payback on Evaporator investments: Significant savings with improved productivity Higher throughput Labor and cost savings from far lesser shutdowns Who should attend? Business Owners and CXOs Plant Head/Production Head Production and Maintenance Heads Process Plant and Design Consultants EPC/Procurement Consultants   Registration link:- https://attendee.gotowebinar.com/register/7335292177682347536 Get in touch to know more #### Engineers Day – Then and Now Honouring Sir Mokshagundam Visvesvaraya’s Legacy Every year, on September 15th, India celebrates Engineers’ Day in honour of one of its greatest sons, Sir M. Visvesvaraya. A man of exceptional engineering prowess and unwavering commitment to his nation, Sir Visvesvaraya’s legacy continues to inspire engineers to this day. Born in 1861, Sir Visvesvaraya’s engineering achievements left an indelible mark on India’s development. He was a great visionary and a practitioner, making significant breakthroughs in water resource management. His expertise in building dams and irrigation systems fulfilled the critical needs of a young and growing nation. What set him apart was his unyielding ethics, total sincerity, and an unshakable belief in the power of Indian ingenuity. Sir M. Visvesvaraya’s work exemplified the spirit of dedication and his unwavering commitment to the betterment of the nation. What can we learn from the life of Sir M. Visvesvaraya? We must remember that securing water is a noble goal. Sir Visvesvaraya’s most iconic contribution to water management was his involvement in designing and constructing the Krishna Raja Sagara Dam (KRS Dam) across the river Cauvery in Mysore, now Karnataka. This engineering marvel, completed in 1931, not only provided a reliable water supply for irrigation but also generated hydroelectric power. Sir Visvesvaraya’s meticulous planning and engineering skills ensured that the dam served its intended purpose efficiently, benefiting farmers and the region’s economy. His ethical commitment to fulfilling the water needs of the people and sustainable development is evident in the KRS Dam’s enduring legacy. Today, as we develop advanced technologies for wastewater treatment, we must keep the intent of treating as a noble goal. Modernisation, Reforms and Advocacy for Water Conservation can only succeed with the complete dedication of all. Sir Visvesvaraya strongly advocated for water conservation and equitable distribution throughout his career. He championed irrigation reforms and emphasized the importance of efficient water management practices. His ethical stance against wastage and his dedication to the welfare of the farming community was evident in his efforts to modernize irrigation systems and promote responsible water use. In today’s cost-centric context, net water-positive commitment requires total modernisation, compliance reforms and, above all, a commitment from everyone to this noble goal. Remember the importance of ethical leadership. Water is a welfare resource, not our private property.  Sir Visvesvaraya’s ethical principles extended beyond his engineering projects. As a public servant and statesman, he served with integrity and dedication. Set a high standard for others in the public service sector. His leadership in various administrative roles, including as the Diwan (Prime Minister) of Mysore, demonstrated his unwavering commitment to the welfare of the state and its people, including managing water resources. We must follow and fulfil our responsibility towards ‘water’ with the same high ethical standards in today’s world. In these examples, Sir Visvesvaraya’s ethics are evident in his dedication to serving the greater good, his commitment to sustainable water management, and his advocacy for responsible resource use. Today, his legacy resonates with a new generation of engineers determined to take India forward by addressing one of its most pressing challenges – water scarcity. The goal is no longer to meet the nation’s water needs but to achieve a net water-positive status. This requires a holistic approach to water management, which he championed long before it became a global imperative. The picture today! In the modern era, engineers are building Zero Liquid Discharge (ZLD) systems, wastewater recovery technologies, and advanced purification systems. They work tirelessly to ensure that every drop of water is used efficiently, treated effectively and conserved diligently. Clean water, a fundamental human right, remains a challenge in India and worldwide. Engineers today, inspired by the principles of Sir M. Visvesvaraya, are at the forefront of the battle to provide clean water to all. His wisdom and approach to engineering continue to guide us as we navigate complex water-related challenges. We have learned that water is not an isolated issue but deeply intertwined with agriculture, industry, and environmental sustainability. Engineers now understand the importance of a more interrelated approach to water management, focusing on recycling, reducing wastage, and creating self-sustaining ecosystems. As we commemorate Engineers’ Day, remember that while the technologies and challenges have evolved, the values guiding Sir M. Visvesvaraya remain unchanged. Commitment, integrity, innovation, and an unwavering belief in the power of engineering to transform lives are the attributes that make great engineers, and they are the legacy he left behind for generations to come. In a world where the pursuit of knowledge and progress never stops, may Engineers’ Day be a reminder that we stand on the shoulders of giants like Sir M. Visvesvaraya and carry forward the torch of innovation, engineering excellence, and the dream of a better, water-sufficient world. #### Evaporators: Types and uses Evaporators are used to convert liquids into gaseous state via heat transfer. All of the basic evaporators have mechanism to separate liquid and vapor by means of a heat transfer. The raw material fed into the evaporator and passes through heated tubes. The heat evaporates the water within the raw material. Application of evaporators Evaporators are used widely in processing industries that work with fluids and chemicals. They work best in low-temperature applications in food and pharmaceutical industries and in effluent treatment. Apart from manufacturing reliable and cost-effective evaporators for over two decades, Shachi has recently introduced the new self-cleaning evaporator in India in collaboration with Klaren International BV from Holland for effluent treatment. Types of evaporators Evaporators are distinguished into different types based on the way they achieve the heat transfer. For instance, the working of forced circulation evaporators relies on pumps to circulate the feed whereas falling film evaporator design calculations rely on gravity. Based on their designs, evaporators can be classified into following types: Forced circulation evaporators consist of tubular heat exchangers for concentrating a feed. Forced circulation evaporator is deployed in cases where there is a high chance of feed or product liquor slating or scaling, or when the feed has high viscosity and the thermal and flow properties of the process liquor are poor, rendering forced circulation necessary. In the forced circulation evaporator mechanism, the feed is pumped at high velocity through the tubes to ensure high heat transfer coefficient. Forced circulation evaporator working is best suited for crystallization of slurries and other solutions. The working of forced circulation evaporator achieves high velocities and low residence time in a small space due to high heat transfer. This prevents the feed from reacting with the vessel of the forced circulation evaporator. Thus, forced circulation evaporator mechanism greatly reduces or eliminates altogether, the possibility of scaling. Rapid evaporation makes forced circulation evaporators suitable for processing thermonuclear substances. . The use of pumping in forced circulation evaporator mechanism also makes forced circulation evaporators the best fit for viscous preparation. The rising film evaporator is essentially a shell and tube type heat exchanger. The liquid to be evaporated is fed into the evaporator from the bottom of the tube. There is a condensation of steam on the outer surface of the vertical tubes, and the liquid within the evaporator boils up into vapor. As the liquid progresses up the tube, the volume of vapor being generated increases leading to a higher central core velocity. This velocity in turn forces the liquid to the remaining tube wall, creating a thin liquid film which moves rapidly. The rapid movement of the film leads to high heat transfer coefficient and reduction in residence time of the material. Rising film evaporators are best suited to process materials that have mild scaling tendencies, but they cannot handle heavy scaling and heat sensitive materials. A falling film evaporator is built to solve the problems rising film evaporator faces. Falling film evaporator is best suited to evaporate heat sensitive liquids. As seen in the falling film evaporator diagram here, the feed enters the evaporator from the top and is distributed through the heating tubes. The liquid flows through tubes and forms a thin film on the walls of the tube while being partially evaporated. The heat is provided through the heating medium (generally steam) to ensure high heat-transfer coefficient. The liquid and the vapor then flow downwards under the pull of gravity. In the falling film evaporator working, the co-current vapor flow serves to augment the downward movement of the liquid. Concentrated product and its vapor are then separated from each other at the bottom of the falling film evaporator unit. A standard process followed while material selection which takes into account the feed properties ensures high & efficient heat transfer. The distributor head of the falling film evaporator which feeds into the tubes is designed to ensure uniform wetting of the tube surfaces thus avoiding any crusting which is the root of major maintenance problems pertaining to falling film evaporators. Shachi’s experience in falling film evaporator design calculations clubbed with high end design capabilities and meticulous manufacturing practices ensure that the falling film evaporator carries out your process in exactly the required way. Agitated thin film evaporators consist mainly of jacketed shells and high-speed rotors. Working principle of the agitated thin film evaporator involves the feed entering the evaporator from the top. As shown in the agitated thin film evaporator diagram here, the feed is then agitated and spread out into a thin film on the shell walls by the fast spinning rotor. The liquid is distributed in the form of a thin film on the heated wall where the heat transfer takes place. Further on, the rotor inside the heating shell wipes the fluid film from the walls. Hence, agitated thin film evaporator is also called as Wiped film evaporator. Agitated thin film evaporators are used mostly for fluids that possess high sensitivity and high viscosity. Agitated thin film evaporator working principle enables businesses to achieve extremely high and specific evaporation rates. The vapors generated within the ATFD evaporator after heating flow concurrently are cleaned using an entrainment separator. The turbulence helps the thorough heat transfer and mechanically ensures that the entire mass undergoes the process to produce high yields from 30% to 80% concentration possible in a single pass. Intensive mixing process within the ATFD evaporator also serves to protect temperature-sensitive products from overheating. Multi effect evaporator operation is a process where multiple evaporators are used, and the water vapour discharged from one effect is used as the heating medium for the next effect which has a lower boiling point. Multi effect evaporator is widely used for concentrating aqueous fluids, and enables businesses to obtain the product at the lowest temperature. One or more bodies operating at the same boiling temperature are defined as one ‘effect’ of a multi-effect evaporator. In the multi-effect evaporator, the first effect is heated with raw steam and the other effects are arranged in an order of subsequently reducing boiling points. The multi effect evaporator working principle enables the operation to reuse the latent heat in the water vapor. As the vapor pressure of the second effect relative to the first effect is lowered, the boiling point of the second effect in the multi effect evaporator is also lowered. The feed moves from high pressure to low pressure in multi effect evaporator, which eliminates the need to pump the feed. The feed arrangement in a multi effect evaporator can be done in forward, backward, mixed or parallel manner. The operating principle of the self-cleaning evaporator is based on the circulation of solid cleaning particles through the tubes of a vertical shell and tube heat exchanger. The fouling liquid flows upward through the tube bundle of the heat exchanger which incorporates specially designed inlet and outlet channels. Solid particles are fed to the fluid through the inlet channel. A proprietary distribution system is employed to ensure a uniform division of particles over all the tubes. The particles are fluidized by the upward flow of liquid, where they create the mild scouring effect on the wall of the heat exchanger tubes, thereby removing any deposit at an early stage of fouling formation. After the tube bundle the particles disengage from the liquid in the separator and are returned to the inlet channel and the cycle is repeated. Procuring reliable and cost-effective evaporators in India The efficiency of evaporators is determined to a considerable extent by the design and capabilities of the evaporator. Factors such as construction materials, energy efficiency and carbon footprint of the evaporator should be considered when choosing an evaporator suitable for your application. Shachi works to deliver exact results as per your requirements on these fronts. Backed by experience of over two decades, Shachi has successfully installed 350+ projects in 5+ countries for over 225 clients. Infrastructure and documentation that meets global standards ensures that Shachi’s designs give an edge to the customer. Our design process begins with a thorough study of customer processes and requirements, and evaporation solutions are designed using advanced analysis with CFD technology. To know more, get in touch! Get in touch to know more #### Exploring Sustainable Solutions with Shachi Engineering at IFAT India 2023 In the heart of Mumbai, a momentous event is on the horizon – IFAT India 2023. This respected expo is a hub of innovation, sustainability, and advanced technology, and Shachi Engineering is proud to be a part of it. Shachi’s Vision for IFAT India Shachi Engineering, with 25 years of experience, specializes in industrial drying and evaporation technology. At IFAT India, we will introduce our “Zero Liquid Discharge Plant” solution. Over the past two decades, we have gained recognition for our commitment to excellence. Our expertise covers the entire ZLD spectrum, offering a comprehensive turnkey solution from concept to commissioning. Our ZLD solution includes critical components such as strippers, evaporators, and pre & post-evaporation systems like RO, ETP, centrifuge, ATFD, and spray drying plants. Why Visit Us at IFAT India 2023? If you are dealing with challenges such as critical effluent treatment, frequent ZLD plant shutdowns, or high operational costs, we have the solutions you need. Join us at IFAT India 2023 at the Bombay Exhibition Centre (Hall – 1, Stall No – 52) from the 17th to the 19th of October. Here, you can explore a range of sustainable solutions, all in one place, with Shachi Engineering. In an ever-changing world where environmental awareness and industrial efficiency are essential, Shachi Engineering is your trusted partner. Come and be a part of our journey towards a cleaner, more sustainable future. Discover innovation, sustainability, and excellence at IFAT India 2023, and let Shachi Engineering guide you toward a brighter tomorrow. #### Factors to be considered in spray drying process Spray drying process removes the moisture from liquids to turn it into powdered form without considerably changing their nutritious value or core chemical properties. It increases the product shelf-life without the need for refrigeration, and thus, is a key process in food and pharmaceutical industry, along with other sectors where spray drying is also used. Quick processing, precise, consistent particle size, and solubility are the hallmarks of a perfect spray drying process. Spray dryer requires consideration of factors related to two key aspects, the properties of the feed material and the efficiency of the dryer. A) Factors to consider in feed properties Technically, spray drying can convert any liquid product into powdered form. However, the chemical properties of the feed must be considered not only from particle consistency point of view, but also in terms of safety of the equipment. Here’s how chemical properties of the feed can affect the dryer system and the drying process. pH factor: Feeds with a high pH factor can corrode the walls and damage the equipment. Flammability: Certain feeds can be flammable or prone to explosion. In such cases, adequate safety precautions need to be taken during the spray drying process. Hydroscopic properties: Products that tend to attract water, present additional challenges for drying Abrasive properties: If the feed is abrasive, it will damage the equipment at vital points as it runs through the spray dryer system. It could damage piping system, pumps, walls etc. Thermoplastic properties: Lower glass transition temperatures of thermoplastic materials such as certain resins tend to create additional challenges in drying. The viscosity of the feed determines how smoothly it will flow through the spray dryer system. As the liquid moves, the motion of the particle relative to one another develops shear stress. Adjacent layers of the fluid tend to move at different velocities than one another. Key decisions regarding batch processing and atomization techniques can be made only after considering whether the viscosity of the feed increases or decreases with the shear. This information also helps to determine the best way of cleaning the equipment after the operation is completed. Spray drying is best suited to dry heat-sensitive products. However, if the liquid has very low heat sensitivity, it will be difficult to achieve a desired result by heating it. One the other hand, extremely high heat sensitivity also poses challenges in spray drying and can limit the dryer capacity. One factor that deeply impact the product throughput is the amount of solid present in the feed. Learning the exact percentage of solid in the feed is key from dryer efficiency perspective. Firstly, it tells us whether the feed will be successfully evaporated or whether it would exceed the evaporation capacity of the dryer, which is not an ideal situation. Secondly, If the percentage of solid content is high, it translates into lower evaporation of the feed and a higher production rate. In many cases, the feed material could be an emulsion, a suspension or a colloid. The efficiency in spray drying depends considerably on the structure of emulsions. Coalescence of emulsions is a serious problem in spray drying. In addition, suspension materials will witness an uneven flow if there is excessive settling out. The final product will be affected and the dryer system will have jammed nozzles. Specific gravity is a factor to consider when working with fluids other than water. Specific gravity is the ratio of a fluid’s density in comparison with water. The specific gravity of water is always held as 1. Specific gravity helps to decide product throughput in the spray drying operation. B) Factors to consider in spray dryer When nozzle atomizers are used, atomization of the feed is done under pressure. The chemical properties of the feed material and desired droplet size in turn influence the selection of the atomizer. The pressure applied during this process influences the droplet size. The higher the pressure, the smaller the droplet size of the final product. You can find additional information about the working of different atomization systems in our blog here. Inlet temperature is the temperature of the drying gas, measured just before it enters the drying chamber. The higher the inlet temperature, the higher the evaporation rate of the solvent. However, simply increasing the inlet temperature does not necessarily yield the best final product. On the contrary, high inlet temperature can affect the wet-bulb temperature of the surrounding air, and leads to thermal degradation of the final product. The calculations for level of inlet temperature to be maintained depend on the properties of the feed material. The volume of drying gas injected into the drying chamber per unit time is known as the gas flow rate. If the gas flow rate is high, it increases the efficiency of the cyclone within the drying chamber, but air-droplet interaction is minimized, and movement of particles increases. Thus, the gas flow rate should be maintained just enough to ensure evaporation of moisture and the separation procedure that follows. Outlet temperature is the temperature of air holding the dried particles, measures prior to deposition of these particles in the collector. In theory, this is the maximum temperature to which the product can be heated. However, it does not stand true in all cases. IN case of counter-current dryers, the outlet air might have a lower temperature than the final product. Residence time is the time feed material droplets spend inside the drying chamber. This factor directly impacts the quality of the final product. Residence time should be calculated correctly to dry the liquid feed yet retain its core chemical properties. Ideally, the residence time is a few seconds, with fine particles not spending over 15 seconds in the chamber. Conclusion From feed properties to movement of particles within the drying chamber, a number of factors must be considered for a successful spray frying process. Achieving precision in the process requires a combination of technology, expertise and experience. Shachi Engineering has over two decades of expertise in drying process for diverse industrial applications. We have proven experience and expertise in spray dryer designing, manufacturing till commissioning at customer sites that meets global standards. Apart from having pilot plants for development and testing purpose, Shachi Engineering provides advanced simulation and analysis of the drying process using CFD technology to make your process more efficient and cost effective. Get in touch to know more #### From Strangers to a Family – Shachi’s Induction Program Joining a new company can be a nerve-wracking experience, but at Shachi, the induction program is not just a routine affair; it’s a heartfelt initiation into a family-like culture. From the moment new employees step through the doors, they are enveloped in an atmosphere of warmth and camaraderie, setting the tone for a journey beyond professional roles.Meeting the Faces Behind SuccessWhat makes Shachi stand out is its commitment to personal connections. The induction program provides a unique opportunity for newcomers to meet not only their immediate colleagues but also the heads of departments. This direct interaction with key figures in the company fosters a sense of openness and accessibility, making the workplace feel like a community where everyone’s voice matters.“As a new employee, the introduction to my colleagues helped me build relationships and feel welcomed in the organization”, says Shubham from Marketing.Values Beyond PoliciesShachi’s induction program is not a mere rundown of policies and procedures; it’s an immersive experience that delves into the company’s rich history and vibrant culture. By emphasizing the alignment of personal and company values, new employees are not just joining a workforce; they are becoming integral parts of a shared mission. This alignment lays the foundation for a sense of purpose that transcends individual roles.“The Induction Program helped me quickly integrate into the company culture and understand how my work contributes to our shared goals. I feel supported and valued as a new employee!” Exclaims Karan working in Shachi’s Production Department.Beyond Training – Building ConfidenceThe comprehensive training provided during the induction is more than a toolkit for daily tasks; it’s a confidence-building journey. Shachi’s approach instills a belief in each employee’s potential, creating an environment where individuals feel supported and valued. This investment in personal and professional growth sets the stage for success, both for the employee and the company.“I feel confident using the skills I learned and appreciate the comprehensive approach taken by the company”, quotes Tushar from Sales & Proposals.From Colleagues to CompanionsThe heart of Shachi’s induction program lies in the emphasis on building relationships. Introducing colleagues is not just a formality; it’s a genuine effort to foster collaboration and communication. This intentional focus on connection creates a positive work environment where employees feel not just accepted but embraced.In conclusion, Shachi’s induction program goes beyond the ordinary. It’s a journey that transforms strangers into family members, instilling a sense of belonging that resonates in every aspect of the workplace. At Shachi, success is not an individual pursuit; it’s a collective endeavor fueled by the warmth of a company that truly values its people. #### Gaurav’s Growth Story – Remarkable Journey from Engineer to Leading a Prestigious Project in Under 8 Months The urge to change… When there is a genuine urge to expand and grow, change is natural. Gaurav wanted to go beyond his skillset and explore a broader set of opportunities. Shachi offered suitable projects and environments for his growth. Gaurav joined the Shachi team as an Engineer in early 2023. In his previous role, his work was primarily limited to structural engineering. He had over 3 years of experience. At Shachi, he found a team and place that would allow him to expand his capabilities and take on a leadership role. The urge to change… When there is a genuine urge to expand and grow, change is natural. Gaurav wanted to go beyond his skillset and explore a broader set of opportunities. Shachi offered suitable projects and environments for his growth. Gaurav joined the Shachi team as an Engineer in early 2023. In his previous role, his work was primarily limited to structural engineering. He had over 3 years of experience. At Shachi, he found a team and place that would allow him to expand his capabilities and take on a leadership role. Gaurav’s dreams did not have to wait! At Shachi, Gaurav quickly got the opportunity to venture into new territories and explore production and on-site projects. As a Production and Site Engineer at Shachi Engineering, he found himself in a dynamic, multi-departmental setting aligned with his career aspirations. Credit also goes to the Talent Team at Shachi, which was instrumental in building Gaurav’s competencies and identifying the right opportunities for him. Taking project leadership One of the highlights of Gaurav’s journey at Shachi was when he took the lead on a prestigious project at our Dahej factory. His leadership skills shone brightly as he successfully led the project by coordinating with multiple departments and solving complex problems. This was the first time for me to independently lead a project. At Shachi, I got to expand my learning from mostly a structural engineering base to a wide range of areas in process engineering. I was thrilled to take up the opportunity. I now feel confident about leading even bigger projects! Driven by curiosity, Gaurav delved deeper into the production of advanced spray coolers – a speciality of Shachi Engineering. With the guidance of experienced mentors at Shachi, he had something new to learn every day and at every step of the project. With independent responsibility, he felt a change in the efficiency of his daily routine work. Shachi Engineering’s disciplined work environment, supportive learning environment, and growth opportunities aligned with competencies ensured Gaurav’s successful transformation into a leader. Gaurav’s story shows us the power of embracing change and pursuing your passion. If you are looking to change your story, Shachi Engineering is always looking for the right talent. You can apply here. #### Happy New Year 2021 Happy New Year 2021 During covid-19 pandemic, opportunities were disappearing… yet we firmly believed in creating new ones. Covid-19 brought many businesses to a halt and affected people’s lives. However, when the pandemic was stealing business and employment opportunities, we continued our sincere efforts to strengthen our business and support our people. Now, as we are steadily recovering from the impact of Covid-19, we are all set to grow further and empower more people. We wish all our customers, vendors, employees and various business associates a very HAPPY NEW YEAR 2021. #### How CFD Improves Spray Dryer Design for Accuracy and Predictability Spray drying works best when airflow, droplet formation, residence time, and capture are aligned to the product spec. Computational Fluid Dynamics (CFD) lets engineers test and tune these variables before fabrication or commissioning, cutting guesswork and reducing trial iterations. Chamber Airflow: Designing the Drying Path CFD first clarifies chamber airflow. By mapping how hot air enters, mixes, and moves through the chamber, it reveals velocity fields, temperature gradients, and recirculation zones. Designers then adjust inlet geometry and angles to avoid dead zones, set residence time so droplets dry within the intended window, and smooth flow near surfaces to reduce wall deposition. Particle Behavior: Linking Air to D50/D90 It also links particle–air interaction to particle-size distribution (PSD). Particle tracking shows droplet trajectories and evaporation paths, tying airflow to D50/D90 and final moisture. With volumetric distribution across the chamber, engineers can anticipate where coarse or fine fractions migrate and identify zones prone to agglomeration or fines carryover. Atomization Settings: From Spec to Droplet Band On atomization, CFD moves decisions from trial-and-error to spec-driven settings. For pressure nozzles, it relates pressure and orifice selection to target micron bands. For rotary atomizers, it helps tune wheel diameter and speed (escape velocity) to set initial droplet size and spread. The result is an initial droplet band that sits close to the requested PSD before the first run. Cyclone Efficiency and Stable Start-ups Capture improves as well when cyclones are modeled. Refining inlet orientation, body proportions, cone angles, and pressure-drop trade-offs raises mechanical efficiency and reduces fines to the exhaust, improving yield and keeping stacks cleaner. CFD also smooths scale-up. It provides a bridge between pilot and plant by normalizing for changes in air temperature, humidity, and load. Sensitivity checks flag small shifts in flow or temperature that can degrade PSD, and the model produces practical set-point bands for airflow, temperatures, and atomization that guide commissioning. Utilizing CFD to get best results Good inputs make CFD useful. Target PSD (D50/D90), moisture, and bulk density must be paired with feed properties such as solids percentage, viscosity, surface tension, and solvents. Thermal limits (inlet/outlet air temperatures, heat balance) and hardware constraints (chamber size, available pressure/flow, filter or cyclone limits) round out a model that mirrors reality closely enough to drive decisions. In practice, teams see tighter PSD on early batches, steadier operation windows across seasons and shifts, lower wall build-up, higher cyclone capture, and fewer start-up iterations. The bottom line is that CFD turns spray dryer design from “test and tweak” into a data-led process. The Shachi Way Shachi has applied CFD to spray drying for the last eight years, helping plants achieve the specified particle sizes, cleanliness, and capture targets with greater confidence and predictability. #### How CFD improves Spray Dryer Performance When the stakes are high, knowing what is going to happen in advance could save lots of time and effort put in wrong places. If you had tools that could predict how your throughput is processed before you even put in to the machine, it could save you a lot of costs. That is what the CFD technology does in case of spray drying. Computational Fluid Dynamics (CFD) entails application of mathematics, physics and computer softwares to simulate how a fluid flows and how it affects other objects around it. CFD originated in the early 20th century and was mainly used to measure he flow of air around cars and aircraft. Later, it proved to be useful in sectors such as spray drying. In this blog, we take a closer look at how CFD is used in spray drying process. CFD deals with the mass transfer, heat transfer and the momentum transfer of fluids in consideration. With the help of CFD tools information such as the flow pattern in the chamber, particle-air interaction, temperature profile, particle trajectory etc. can be gathered and leveraged to improve efficiency of drying system, economically. Computational Fluid Dynamics (CFD) is the science of predicting fluid flow behaviour, momentum transfer, heat transfer, mass transfer and many other process associated with it. The information is gathered by solving mathematical equation which govern these process using numerical process. In context of spray drying technology, CFD helps to answer many questions which are critical to its performance and results. Particle behavior inside Spray Dryer Chamber CFD models are useful in determining the Velocity Field. The flow characteristics in the chamber can be identified to understand the velocity does hot air and particle. CFD Analysis provides knowledge of the exact velocity of the particle heading towards wall, its moisture content, temperature etc. which can be then used to improve the process. Temperature of elements Spray Dryer Chamber With CFD model, we can come to know the Temperature of various elements in the chamber. For instance, the temperature of hot gas across the chamber, duct, cyclone and entire equipment can be known using CFD. Using the know-how on temperature aids several decisions such as the best suitable insulation, optimum material thickness to resist temperature changes and more. Problem associated with thermal expansion can be identified in the analysis and fixed with appropriate solutions such as suitable metallic bellow. Forces Exerted on the particle in Spray Dryer CFD Analysis is well proven to know the forces and their optimum magnitude on the particle. For instance, in the cyclone separator centrifugal force acting on the particle which can separate the particle from gas stream, stresses acting on the metallic bellow, storage tanks etc. can be accurately understood by conducting CFD analysis. CFD analysis forms an integral part of standard operating procedures at Shachi engineering. we have establishd advance simulation and analysis using Computational Fluid Dynamics (CFD) techniques. Our team has many years of expertise in designing of spray dryer with optimum performance and successful delivery of 500+ plants with promised features. To know more about how our spray driers could help your business grow, get in touch with us. Get in touch to know more #### Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in spray drying operations. Every stoppage affects production, delivery schedules, manpower planning, product quality, and profitability. In many plants, downtime is accepted as routine. A cleaning stop here. A blower issue there. A control problem during operation. Over time, these small interruptions become a major financial loss. That is why downtime control should not begin after commissioning. It must begin at the design stage itself. Process-Matched Automation Prevents Unstable Operation Automation in a spray drying plant is not just about panels, buttons, and alarms. It must match the actual process requirement. It should respond correctly to temperature changes, feed rate variation, airflow behaviour, pressure conditions, safety limits, and alarm situations. When automation is not selected or configured properly, operators struggle to maintain stable conditions. Small deviations become difficult to control. This can lead to repeated stoppages and production loss. A well-designed automation system makes the plant easier to operate, monitor, and control Reliable Components Reduce Unexpected Failures A spray drying plant depends on many critical components. Pumps, fans, blowers, atomizers, rotary valves, and other moving parts work continuously under demanding conditions. If these components are not selected properly, failures can become frequent. One weak component can stop the entire plant. This is why component selection must be done with a clear understanding of duty cycle, load conditions, product behaviour, maintenance access, and long-term reliability. Deposition Control Improves Uptime Product deposition inside the chamber is a common reason for stoppages. Build-up affects drying efficiency, airflow movement, product quality, and cleaning frequency. In some cases, it can also increase safety and maintenance concerns. Deposition control depends on the right chamber design, airflow path, atomization, temperature profile, product behaviour study, and operating conditions. At Shachi, all these points are considered seriously during plant engineering. From basic engineering to detailed engineering, every parameter is evaluated through calculations, process knowledge, and simulation-backed validation. Because reducing downtime is not only about faster maintenance. It is about designing a plant that runs reliably for longer periods. That is how Shachi helps customers improve uptime, protect production, and reduce lifecycle losses. This is why Shachi is trusted as the No.1 Partner for Spray Dryers and Beading Plants. #### Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily on two recurring costs: electrical power and fuel. These costs do not appear as a one-time expense. They continue every day, every batch, and every production cycle. If power and fuel efficiency are not controlled at the design stage itself, the plant can quietly lose money throughout its lifecycle. This is why the design of a spray drying plant must go beyond capacity and equipment size. It must look closely at airflow, ducting, pressure drops, heat generation, heat transfer, and operating efficiency. Power Loss Begins with Poor Airflow Design Fans and blowers are among the major power-consuming components in a spray drying plant. When ducting is not sized properly, when bends are not planned correctly, or when pressure drops across equipment are too high, the system needs more power to move air through the plant. This increases electricity consumption every day. A well-designed plant controls pressure drops from the beginning. It uses the right duct sizing, proper equipment layout, smooth airflow movement, and accurate pressure drop calculations. This reduces unnecessary resistance and helps improve power efficiency. Fuel Loss Begins with Poor Heat Utilisation Fuel is another major cost in spray drying. The plant must generate the required heat load efficiently. This depends on the heat transfer area, hot air generator selection and design, heating medium, airflow temperature, and overall thermal efficiency. If heat transfer is poor, the plant burns more fuel to achieve the same drying result. Over time, this becomes a major operating loss. A carefully designed system improves heat utilisation. It helps achieve the required drying performance with better fuel efficiency and lower recurring cost. Low Capex Can Become Expensive Later Many buyers compare spray drying plants mainly on initial cost. But a lower-cost plant can become expensive if it consumes more power, burns more fuel, needs more maintenance, or delivers lower efficiency. The real cost of a spray drying plant is not only the purchase price. It is the cost of running the plant for years. At Shachi, these points are considered seriously at the design stage itself. Power consumption, fuel efficiency, pressure drops, ducting design, hot air generator selection, heat transfer, and lifecycle performance are evaluated before the plant is built. Because the right spray drying plant does not just dry the product. It protects profitability throughout its operating life. #### Inauguration of New facility – at GIDC-Saykha, Bharuch, Gujarat Towards a bigger and brighter future! Shachi Engineering now stands at a moment that is both proud and humbling. Recently, Shachi established a new facility in Bharuch, thereby doubling its manufacturing capacity. While this was indeed an achievement, it also served as a juncture to reflect on where we came from and remind us of the responsibilities that we carry. In its two-decades-long journey, Shachi Engineering has continuously strived to deliver top-quality performance and excellence in design that enables its clients to scale up internationally. It is their growth that has in turn empowered Shachi Engineering to take this big step today. Underlining the value that its roots and its clients hold for Shachi Engineering, the new plant was inaugurated by Mr Jayendrabhai Kharawala, who was our first customer back in 1998. Mr Shyam Bhai Kabutarwala, Director of Colourtex Ltd graced the function as Guest-of- honor. The inauguration ceremony saw participation from over 150 well-wishers, employees and clients. In line with the company’s commitment to sustainability and the environment, a tree plantation drive was also conducted on the premises of the new manufacturing plant. We also take this opportunity to welcome you all to visit the new facility! Get in touch to know more #### Inauguration of New facility – at GIDC-Saykha, Bharuch, Gujarat Towards a bigger and brighter future! Shachi Engineering now stands at a moment that is both proud and humbling. Recently, Shachi established a new facility in Bharuch, thereby doubling its manufacturing capacity. While this was indeed an achievement, it also served as a juncture to reflect on where we came from and remind us of the responsibilities that we carry. In its two-decades-long journey, Shachi Engineering has continuously strived to deliver top-quality performance and excellence in design that enables its clients to scale up internationally. It is their growth that has in turn empowered Shachi Engineering to take this big step today. Underlining the value that its roots and its clients hold for Shachi Engineering, the new plant was inaugurated by Mr Jayendrabhai Kharawala, who was our first customer back in 1998. Mr Shyam Bhai Kabutarwala, Director of Colourtex Ltd graced the function as Guest-of- honor. The inauguration ceremony saw participation from over 150 well-wishers, employees and clients. In line with the company’s commitment to sustainability and the environment, a tree plantation drive was also conducted on the premises of the new manufacturing plant. We also take this opportunity to welcome you all to visit the new facility! Get in touch to know more #### New Age IIoT Enabled Evaporators Evaporation is a highly energy-intensive process. Typically, it consumes 15% to 35% of the total energy consumed by the entire process. Down time for cleaning and ensuring timely cleaning requires proper planing and close watch by production team. Evaporator or for that matter any process plant has expensive operations. Thus continual operations and ensuring maximum efficiency are important aspects manufacturers. Having a better control and right information are key aspects for for faster decision making. Shifting to equipment those are IOT or IIOT ready becomes the need of an hour. IOT gives lot of advantages to customers. Customer gets better control with real time monitoring, historical data for analysis and a data driven decision making. Here are top four areas that IOT enabled evaporators will help Evaporators are changing! Plan Cleaning Cleaning is one of the dominant aspects in evaporator operation, having minimum downtime and deciding when exactly cleaning has to be done are tricky decision that production manager have to take. With IOT in place, Managers can set parameters to analyze and decide cleaning process is properly planned in production schedule. Increasing Efficiency IOT ensures you get complete control of your production. With real time data combined with analysis with the historical information on material consumption, feed to output ratio, power usage, best practices in the Industry etc you can recommend and implement adjustments in production for better throughput. Quality Control IOT can collect your overall quality data and analyze it with third party or standard norms. It helps you to locate gaps that arise due to raw material quality, its reaction to heat, environmental impact etc. All these input further can be analyzed to identify and correct quality issues. Predictive Maintenance Reactive maintenance brings in sudden downtime, loss of production or quality issues. IOT helps to keep a close watch on equipment health. It compares its heath, age to set standards and norms to identify and alert the decision maker well in advance. This helps manager to properly plan the maintenance schedule. Shachi Engineering Launches IOT Enabled Evaporators With it extensive experience, in-depth understanding and advanced technology becomes one of India first company to launch Smart and IOT enabled evaporators. Get in touch to know more #### Safe, smart & specialised drying for fragrance manufacturer An award winning company Zest Aroma is an award winning company that offers aesthetically superior and most competitive flavours and fragrances and flavours that match stringent global quality standards. The flavours and fragrances are used and blended with products of leading Indian and international brands. The company is also recognised for its high sensitivity to environmental issues and has one of the most advanced systems for processing of harmful waste from its plants. Challenge Safety and Quality Flavours and Fragrances are highly volatile products. It becomes a critical challenge in the drying process. Additionally, the manufacturing process has to comply to one of the most stringent safety and quality norms for any products. Risk of Explosion The volatile nature of the product means the plant is prone to risk of explosion and has to have all the checks to arrest fire, if it occurs, at its root. The plant had to have the right balance in ensuring safety, quality and performance for Zest to have a profitable product line in years to come. Shachi Engineering was entrusted with the critical task, owing to its long standing expertise and a strong reference list for plants that manufactured ‘quality’ products. Solutions Ensuring quality Safety and quality were critical to the very functioning of the plant at Zest Aroma. Shachi’s team invested time to understand the specific requirements, its linkages within the process stages before designing the solution. With a comprehensive understanding of the process, Shachi Engineering was able to propose a solution that not just met the Client’s manufacturing need but would also allow the staff to drive production confidently. Arresting Safety Challenges To ensure safety the Spray Dryer plant was integrated with several fire arrestors, at critical points. The accessories and automation in the plant had to be all certified for fire resistance. Even the doors used to access the plant were with an explosion proof design. Safety was critical can be gauged from the fact that the investment in Spray Dryer plant and that on measures to improve the safety were almost equivalent. Shachi’s Spray Dyer was embedded with logic for enhanced safety. The robust construction, quality workmanship and engineering further ensured highest order of safety and quality for Zest’s products. Results Assured aesthetic quality, critical to the product Completely safe and efficient process Minimal maintenance with high quality engineering #### Sales Training Program – Shachi Engineering At Shachi Engineering, we believe in improving customer experience by each passing day. Recently, on 13th February, we organised an exclusive sales training program for our sales team. The program included key strategies and processes to ensure excellence customer experience at every customer touch points. Mr. Kiran Ajwani, a renowned business coach and management consultant conducted the program. #### Shachi at IFAT India 2025: Speciality waste water treatment solutions Mumbai, 14–16 October 2025 — At IFAT India 2025 (Hall 6, Stall G35), Shachi put a clear message on the table: recover more water, cut OPEX, keep compliance simple. Visitors saw our ETP & ZLD approach end-to-end—pretreatment, MEE with TVR/MVR, crystallizer + centrifuge, ATFD for the last mile, and condensate polishing for reuse. The interest was strong from pharma, chemicals, and allied process industries. Thanks to everyone who dropped in and shared their requirements. If you’re planning upgrades or a new ZLD block, we can help map a right-sized train for your site conditions and goals. #### Shachi at KHIMIYA Russia 2025: Moscow, you were great Moscow, 10–13 November 2025 — Team Shachi had a strong run at KHIMIYA Russia 2025 at the Timiryazev Center. The stall stayed busy, with steady conversations from oleochemical and specialty chemical visitors across the region. Our spotlight was on Beading Plant technology—how we deliver uniform, free-flowing beads and stable operation across winter lows and humid seasons. Many guests also explored the broader line-up: spray dryers, evaporators, ATFDs, and polishing units that complete an export-ready process. A big thank-you to everyone who stopped by and shared their challenges. If you missed the show, we’re happy to connect and walk you through what a right-sized beading line could look like for your products. #### Shachi at PIPOC Malaysia 2025: Beading plants in focus Kuala Lumpur, 18–20 November 2025 — PIPOC 2025 at KLCC delivered exactly what we hoped for: focused traffic from palm oil refiners and oleochemical producers across Southeast Asia. We showcased Beading Plants for Stearic (C18), Palmitic (C16), Myristic (C14), and GMS. Discussions centred on bead uniformity, low fines, cleaner packing to improve overall efficiency. Thank you for the warm response and practical questions. If you’d like a quick walkthrough of options for palm-based derivatives, our team can share configurations and typical duty points. #### Shachi Beading Plant: Built for Global Performance With installations across India, South East Asia, the Middle East, Africa, and the CIS regions Shachi’s beading plants are a proven success in some of the most demanding applications globally. Designed for real-world utilities and climates, it consistently converts molten oleochemicals into uniform, free-flowing beads that meet shipment-to-shipment specs. Why companies choose Shachi’s beading plant 1. Right bead size-700 μm, reliably Precision droplet formation (nozzle design, fall height, velocity) plus staged cooling delivers tight PSD around ~700 μm (+/- 150) with low fines, validated by sieve analysis and in-process sampling. 2. Designed for harsh climates (to -25 °C) Engineered for ambient swings from -25 °C to high-heat, high-humidity sites: insulated enclosures, conditioned process air, temperature control, cold-start logic, and 50/60 Hz utility flexibility. 3. Quality that meets global standards Oleo-grade stainless construction, clean weld geometry, hygienic design, and dust control. Batchwise traceability and stable bead flowability help pass audits and keep customers satisfied. 4. Multiple products, One Plant Process-driven operation enables quick changeovers, as well as controlled recycling and remelting, allowing you to run different chemistries and size bands on the same plant with minimal cross-contamination. 5. Control & Automation PLC-SCADA with IIoT readiness provides real-time visibility and effective process control over key variables (droplet formation conditions, air temperatures, residence time), alarms, and trend logs for repeatable results. Companies choose Shachi’s beading plant because… Scale-up support that travels well Feedstocks and ambients vary by country. We help transfer your processdroplet formation → residence → final coolingso start-up hits bead size, flowability, and moisture targets quickly Traning & Support From Training to O&M manuals, spares, maintenance plans, and operator guides, Shachi’s expert team is always with you help achieve the right product output. Lifecycle economics, not just capex Designs prioritise energy efficiency, high yield (recycle & remelt), and low unplanned downtime driving down /ton of saleable beads while keeping quality consistent across borders. Ready to evaluate a beading plant that performs anywhere? Share your target bead size (e.g., ~700 μm) and throughput Shachi will map the configuration #### Shachi Celebrates World Environment Day with Team Participation Shachi Engineering celebrated World Environment Day with activities that brought people together for a shared purpose. The event included tree plantation, slogan writing, and board presentation. Each activity helped the team reflect on the role we all play in protecting the environment. Small Actions Create Visible Change The tree plantation activity was a simple and practical step. Team members came together to plant saplings and contribute to a greener workplace. It was not just about planting trees. It was about building a habit of care. Small efforts like these create long-term awareness. Ideas Become Stronger When People Participate The slogan writing activity gave employees a chance to express their thoughts. Many shared simple and meaningful messages on saving resources, reducing waste, and respecting nature. Such activities help make environmental responsibility more personal. They allow every team member to contribute in their own way. Awareness Grows When It Is Shared The board presentation helped bring different ideas into one place. It created a visual reminder of why environmental care matters at work and beyond work. The activity encouraged discussion. It also helped the team look at sustainability as a daily responsibility, not just an annual event. Responsibility Is Part of the Shachi Way At Shachi, environmental thinking is closely linked with engineering. The company works on solutions that support industries while also addressing environmental needs. World Environment Day was a reminder of this larger purpose. It showed that responsibility begins with people, continues through actions, and becomes stronger when practiced together. Shachi remains committed to building a cleaner, greener, and more responsible future. #### Shachi Celebrating Engineer’s Day Engineer’s Day is a celebration of those who dream in designs and build with purpose. At Shachi, this day holds special meaning—it’s a tribute to the brilliant minds who not only craft solutions but also shape the future, one project at a time. With over 100 engineers and 20 designers, Shachi Engineering has been turning challenges into opportunities for 25 years. Every spray dryer, every ZLD plant, is not just a product; it’s a piece of their journey—crafted with care, precision, and an unshakable passion for excellence. From the first concept to the final commissioning, our engineers dive deep into the details, not just to deliver but to make sure what we create is the best it can be for our clients. Today, as we celebrate Engineer’s Day, we honour the dedication that goes beyond the work—where learning and growth happen with every project. At Shachi, engineering is more than just a profession; it’s a craft, a passion, and a continuous journey toward perfection. Every member of our team is part of that journey, growing not just as professionals but as people. And through it all, they prove every day that when passion drives performance, excellence follows naturally. Here’s to the engineers who make the impossible possible—and to the 25 years of learning, growth, and brilliance that got us here. Happy Engineer’s Day! #### Shachi Engineering brings the Founder’s vision into reality for Nisarg Crop Care Fulfilling the needs of the farmer community Nisarg is a leading producer of various types of biotic, organic fertilizers to maintain fields’ fertility and production capacity. The speciality products provide 100% Water Soluble Fertilizers for Indian farmers. The products are critical to fulfilling the needs of the farmer community for chemical fertiliser. Nisarg has end-to-end manufacturing facilities based on international standards. Challenge Critical partical size Nisarg had developed a new product and was looking to build a plant on a completely new concept. The particle size of the end product was a critical factor, given that Nisarg has been a leader in the Indian market for the specialised water-soluble range. Taking up the challenge The top management had approached several leading process plant and equipment manufacturers in the past but most of these companies regretted from developing the solution as per the Client’s need. At Shachi, we love to take up new challenges and were quick to take up Nisarg’s challenges as our own. Solutions Shachi’s team took up the challenge and developed a modern, efficient Integrated Fluidized Bed Dryer for Nisarg’s process. Shachi’s team practically worked besides the Client team to implement the solution and ensure the appropriate results are achieved, consistently. Results Concept to commission for a completely new type of plant for the Client, just as they required Output achieved as per the commitment at proposal stage A hassle free installation and commissioning for the Client's plant with desired output #### Shachi Engineering delivers a CaCl2 plant to the Client in record time Stepping the game for India multi-national GFL is the largest manufacturer of Fluoropolymers resin and Refrigerants in India with a strong presence in the international market. GFL was looking to manufacture CaCl2 on a large-scale to be used in manufacturing of its end products. The Client chose Shachi Engineering for its extensive expertise and proven installations in the Drying and Evaporation technology. Shachi Engineering suggested advanced Evaporator coupled with Spray Dryer for the plant. Challenge Aggressive Timeline GFL’s team was planning to expand the existing set-up rapidly and had set a very aggressive timeline which was almost half of what would be considered normal to deliver such large-scale project from concept to commissioning. Exotic Material The plant was to be manufactured using 904L grade steel – considered to be an exotic material. Solutions Shachi Engineering’s team got into action. Meticulous project planning was key to timely installation and commissioning. Right from the design stage, Shachi Engineering’s team was very careful about every step, whether its process study or manufacturing specifications, to avoid even the slightest delay due to rework or any other reason, given the stringent timelines. Results Turnkey Calcium Chloride Plant in record time End-to-end solution saved time and costs, critical to GFL's project Best-in-class manufacturing with exotic materials #### Shachi Engineering gets recognized as “Emerging ESG Partner” Shachi Engineering, the leading industrial drying & evaporation solutions company recently got recognized as “Emerging ESG Partner” by Aarti Industries Ltd. (AIL). As part of the recognition, a trophy and certificate were presented to Shachi Engineering for its efforts towards sustainability and climate change practices. Mrs. Suruchi Shanbhag, Director of Shachi Engineering received the trophy and certificate during an official ceremony hosted by Aarti Industries.  Aarti Industries is a leading Indian manufacturer of speciality chemicals and pharmaceuticals with a global footprint. Over the last decade, Aarti Industries has transformed from an Indian company servicing global markets to a global entity with several state-of-the-art manufacturing facilities in India.  This recognition is a part of strategic initiatives of Aarti Industries to evaluate and recognize the efforts of its key supply chain partners towards best practices to ensure sustainable business. The process of selecting eligible supply chain partner included a rigorous process and audit by third party auditor to evaluate various parameters and progress made by the supply chain partner company.    Today, sustainability has become extremely crucial and important subject for all the organizations. Sustainability improves the quality of our lives, protects our ecosystem and preserves natural resources for future generations.  Speaking on this achievement, Mrs. Suruchi Shanbhag, Director, Shachi Engineering said, “This recognition is the testimony of our commitment and dedicated efforts towards sustainability. Efficiency, energy consumption, safety are critical parameters considered while designing, manufacturing and commissioning of each and every plant. In fact, the purpose of our business is to accelerate our client’s growth by providing optimally engineered environment preserving solutions, thereby improving overall quality of life”. “Such recognition does motivate us to continuously chase our passion for developing efficient and environment friendly solutions for challenging spray drying and evaporation applications across various process industries”, she added further.  Media Contact: Sandeep Jadhav Marketing Manager Shachi Engineering Pvt. Ltd. M: +91 7030470246    E: sandeep.jadhav@shachiengg.com   #### Shachi Engineering resumes operations at Pune and Gujarat Works   We are back in action! But only with extreme #caution and following every safety measure and practice that’s required. As we begin operations post the #lockdown, it is now all the more important to respect and follow the social distancing and hygiene rules to arrest Covid-19 from spreading further. We must not forget the sacrifices of our #Frontliners (Doctors, Public Servants, Police etc.) to protect us from #Covid-19, so far, and bear the responsibility to conduct ourselves with caution post the lockdown. At #ShachiEngineering, we have always believed that #safety is not a gadget but a mindset. Here’s a glimpse of how our #team is committed to the safety mindset. Together, we shall overcome! #inthistogether Get in touch to know more #### Shachi Engineering’s fastrack delivery of 100KLD ZLD Plant with Advanced Self-Cleaning Technology! Product – Wastewater unit Timeline – 6 months Plant Capacity – 100KLD Project/ Equipment – ZLD plant with advanced self-cleaning technology Summary of the project :  ZLD plant with advanced self-cleaning technology A famous Pharma company recently implemented a Zero Liquid Discharge (ZLD) plant at its new facility in Vizag, India. The plant was designed and supplied by Shachi Engineering, a leading provider of ZLD solutions. The ZLD plant is designed to treat 100 KLD of wastewater from the pharmaceutical manufacturing process. It includes a stripper system to remove low-boiler solvents, a four-effect evaporation plant, a centrifuge, and an ATFD (Agitated Thin Film Dryer). The plant also features self-cleaning technology, which helps to prevent fouling and reduce maintenance costs. ZLD plant with advanced self-cleaning technology Challenges   The main challenge of the project was to design and install a plant that could meet the client’s strict requirements for treating complex effluent generated in Pharma & API industries. Proper treatment of complex effluent is crucial to avoid environmental and health hazards. Companies must comply with regulations and prioritize effluent treatment, which can be done effectively through Zero Liquid Discharge (ZLD) to tackle water scarcity. It’s not only a legal requirement but also a corporate social responsibility to ensure the safety of the environment and society. Solutions ZLD with Self-Cleaning Technology Shachi delivered an innovative wastewater treatment solution by incorporating a steam-based Zero Liquid Discharge (ZLD) technology with advanced self-cleaning technology. Complete ZLD Solution including Stripper System The ZLD plant included a Stripper System to remove low-boiler organic solvents, a four-effect evaporation plant followed by a combination of centrifuge, and an ATFD (Agitated-Thin Film Dryer) for post-evaporation. This integrated approach ensures that no harmful substances are released into the environment, aligning with Valens’ commitment to environmental responsibility. Technical Competency in Steam-based ZLD Plant Shachi demonstrated unparalleled technical expertise in designing and implementing a Steam-based ZLD Plant for the client. Steam-driven ZLD technology provides high efficiency in evaporation and separation processes, effectively treating 100KLD of wastewater from pharmaceutical manufacturing. Prolonged Performance with Self-Cleaning Technology The standout feature of Self-Cleaning Technology is reduced scaling and maintenance costs. It also ensured consistent high performance and extended the plant’s lifespan. By preventing fouling and clogs, The client can rely on its wastewater treatment system for years, reducing the need for costly replacements and downtime. Efficiency Meets Affordability The ZLD plant operates with meagre operational expenses (Opex). This cost-effective approach made it an ideal solution to meet stringent wastewater treatment standards without breaking the bank. By optimizing resource usage and minimizing maintenance needs, the plant delivers outstanding value for long-term operations. #### Shachi Engineering’s Green Commitment At Shachi Engineering, we’re dedicated to protecting our planet. This World Environment Day, we’re excited to share our new initiatives to enhance sustainability and reduce environmental impact. Our environment gives us so much, and it’s our responsibility to give back. Our Commitment to Water Conservation Water is crucial, and conserving it is our top priority. We’re upgrading our effluent treatment and Zero Liquid Discharge (ZLD) plants to use the latest technology. These upgrades will help recycle up to 95% of wastewater, ensuring cleaner water and less pollution. By implementing these advancements, we aim to significantly reduce the environmental footprint of our operations. At Shachi Engineering, we’re dedicated to protecting our planet. This World Environment Day, we’re excited to share our new initiatives to enhance sustainability and reduce environmental impact. Our environment gives us so much, and it’s our responsibility to give back. Our Commitment to Water Conservation Water is crucial, and conserving it is our top priority. We’re upgrading our effluent treatment and Zero Liquid Discharge (ZLD) plants to use the latest technology. These upgrades will help recycle up to 95% of wastewater, ensuring cleaner water and less pollution. By implementing these advancements, we aim to significantly reduce the environmental footprint of our operations. New Environmental Applications We’re launching a new division focused on environmental applications, integrating existing and new technologies to offer complete solutions for our clients. This expansion will allow us to address a wider range of environmental challenges, providing efficient and sustainable solutions. Our goal is to support both new and existing projects with minimal environmental impact, making us a one-stop solution for all environmental needs. Facing Challenges, Achieving Goals We’re committed to overcoming challenges and achieving our vision of environmental leadership. Despite numerous obstacles, our dedication to innovation and sustainability drives us forward. Our advanced solutions will help make a real difference, contributing to a cleaner, greener future. We believe that with the right approach, we can turn challenges into opportunities for positive change. Join Us in Making a Difference This World Environment Day, let’s work together to protect our planet. At Shachi Engineering, we’re committed to doing our part. Join us in our mission for a sustainable future. Together, we can create a world where our environment thrives, and our natural resources are preserved for generations to come. Happy World Environment Day! #### Shachi Foundation Day 2024 Shachi Foundation Day 2024 Shachi Engineering’s 26th Foundation Day was a heartwarming celebration of our journey and the people who make it all possible! Our directors, Marthu and Suruchi Shanbhag set the tone for the day with a beautiful deep prajwalan ceremony that symbolizes hope and prosperity for the future. Our team members, dressed in the vibrant colours of Maharashtra’s Wari culture, filled the atmosphere with joy and tradition, reminding us of our rich heritage. In the spirit of giving back, we spent a touching afternoon at Aniket Sevabhavi Sanstha, sharing meals and precious moments with the children. Their smiles and laughter were the true highlight of our day. Back at the factory, the energy was palpable as we enjoyed a fun-filled sports competition, strengthening our bonds as a team. A particularly special moment was honouring Sanjivani Koditkar, Head of Finance, for her 20 years of unwavering dedication to Shachi. Her journey with us is a testament to the hard work and passion that drives our success. The day was filled with love, joy, and countless memories. Here’s to 26 years of passion-powered performance and many more years of shared achievements and happiness! #### Shachi Launched New Brand Identity, Brand Promise and Values Shachi has launched a new brand identity, brand promise and core company values to reflect its aspirations and promise to customers. The new core company values are articulated to establish the company culture which will further create a unique customer experience and deliver our brand promise. We are committed to build sustainable and profitable solutions, with game-changing innovations. About New Brand Identity: The new brand identity takes inspiration from the previous identity. The blue colour communicates stability, calmness and the red colour communicates ambitions, aggressiveness and passion. The mnemonic creates a shape of the conch shell and each element used in it is derived from our brand promise. The tagline (passion powered performance) truly sets us apart. It reflects our dedication and deep inspiration to deliver superb performance to customers. Our Brand Promise: We build trust We partner in our customer’s success We deliver value to our customers Our Core Company Values: We persist in getting the result we want We take complete ownership of our Work We respect and care for others We empower others to perform their jobs better We value leadership and Innovation We are frugal This is yet another milestone in our journey from being a good to a great company. We are moving forward and you can always expect Passion Powered Performance! #### Shachi won the Rotary Environment Excellence Award At Shachi, we are committed to provide sustainable technology solutions to customers and protect the environment & mother earth. Recently, our efforts got recognized through “Rotary Environment Excellence award 2020” in the silver category for outstanding achievement in environment management. This award truly reaffirms our commitment towards sustainability, health & safety and environment. The award trophy and certificate was presented to our HR officer during an award ceremony on 28th June 2021 at Bharuch, Gujarat. The event was organized by Rotary Club of Dahej in Association with Gujarat Pollution Control Board and Gujarat Cleaner Production Centre, Gandhinagar, Gujarat #### Shachi’s strategic technology collaboration with a niche European Company Shachi’s strategic technology collaboration with a niche European Company helps to bring innovative, self-cleaning systems in evaporators for customers in the Indian market. These Evaportors do not require jet cleaning, thus saving time, reducing costs and maintenance while ensuring seamless production. Shachi Engineering  has been granted the order for 3 new waste water treatment plants for the dye-making industry. The plants apply multi-stage evaporation of which the first and second stage will be configured with the self-cleaning technology. The design of the plant has been optimized for steam efficiency and to have a compact design. The order is granted after a successful project in which one of the existing evaporators of this client was revamped into the self-cleaning system and showed constant evaporation where previously fouling was an important issue. [easy_chart chart_id=’12565′] LESS TIME 111,597 MORE OUTPUT 6,330 NON-STOP 5,038 Advantages of Self-Cleaning Evaporator Technology #### Shachi’s MVR Based ZLD Plant Emerges as a Game-Changer for India’s Top Stainless Steel Manufacturer Industry : Metals (Steel) Product : ZLD Plant for RO reject application Timeline : 22 Weeks Plant Capacity : 30 KLD Project/ Equipment : MVR-based ZLD plant Setting the standard in wastewater recovery for stainless steel plants The client required a new water and wastewater treatment plant as part of its expansion plan in stainless steel manufacturing. Shachi was chosen to supply the 30 KLD MVR-based Zero Liquid Discharge (ZLD) plant for RO reject application based on Proven Track Record (PTR). About the Client It is a leading Indian stainless steel manufacturer with a yearly melt capacity of 2.9 MT and an annual turnover of INR 35,700 crore. It has facilities in Haryana and Odisha, an overseas unit in Indonesia, and a global presence in 15 countries. Their products include slabs, blooms, coils, plates, sheets, precision strips, blade steel, and coin blanks. Challenges Strong technical competency in MVR-based ZLD Plant Proven Track Record in Steel Industry application A cost-competitive ZLD in terms of CAPEX and OPEX Quick supply and commissioning Shachi offers a turnkey solution Shachi addressed these challenges by providing the client with a turnkey solution that included the design, engineering, procurement, construction, and commissioning of the MVR-based ZLD plant. The plant was also equipped with a German-made MVR blower, which ensures its long-term reliability and performance. Up to 50% lower OPEX Compared to the traditional approach of using a steam-based MEE plant, Shachi’s MVR-based ZLD design helped to reduce OPEX by the use of MVR-based ZLD. This helped achieve significantly better water recovery and process condensate quality, with operational cost savings of over 50%. Significantly lower footprint The site demanded a compact ZLD. Shachi’s design was built to meet this critical need. Most traditional designs require a larger space. But with Shachi’s ZLD, the footprint was almost 30% lower than the conventional ZLDs. Which ultimately saved costs in terms of civil and structural requirements. Long-term reliability and performance Shachi chose a German-made blower for the MVR plant. This is due to very high reliability and peak performance without hassle. The blower in ZLDs is often identified as a weak link. Traditional blower designs could have led to sub-optimal performance and posed risks in terms of reliability. Shachi took no chances and ensured the risk to the client was near zero. Meeting environmental regulations made it hassle-free The ZLD plant from Shachi was observed to be 100% compliant with the stringent environmental regulations by the state and center. The plant was to be operational near an eco-sensitive zone, and even a slight gap in compliance could have led to stringent measures such as closure or heavy penalties. Shachi’s plant ensures risk-free operations for the client while meeting sustainability goals. From designing plants with significant cost-savings and meeting the footprint requirements to ensuring cost-effective and highly reliable operations, Shachi helped the client meet all their goals within time and budget. Shachi’s expertise and design viewpoint were vital to creating several advantages in terms of high reliability, significant cost savings, and getting the compliance right the first time. #### Sharing Insights gained from 100+ Industry Leaders at IFAT INDIA 2023 In case you missed visiting Shachi Engineering’s Booth at IFAT 2023, this is a must-read! Know the pulse of the industry Every year, the IFAT exhibition brings together the trendsetters, cutting-edge insights, and a glimpse into the future of environmental and wastewater treatment technology. The event was held in Mumbai from October 17th to 19th at the Bombay Exhibition Centre. Professionals from the water, sewage, waste, and recycling industries converged to display their innovative products and services. Shachi Engineering is leading the way in demonstrating how technology can revolutionize wastewater management for a greener world. At IFAT 2023, we met over 100 industry leaders worldwide. Here’s a specially curated summary of the insights on what’s the pulse of the industry. Here are Shachi’s key insights from IFAT India 2023 Multifold rise in interest for ZLDs The rising interest in ZLDs was a clear indicator of tightening regulatory compliance of wastewater treatment. Zero Liquid Discharge Plants are now a necessity for many industry segments. Several states are now implementing the regulations seriously and penalising industries. Shachi experienced a multi-fold increase (over 3 times compared to previous years) in interest in wastewater treatment plants, particularly ZLDs. If you are still delaying the consideration for ZLDs, the IFAT India 2023 pulse clearly says that’s not a good move. The top concern for most – Operating costs of ZLDs Over 90% of visitors expressed a concern about the cost of running ZLDs. The high operating cost made running the ZLD plant not only challenging but also impacting the bottom line. There was a lot of interest in new innovative solutions that could deliver on sustainability and economics. Given the low operating costs, as compared to traditional ETPs, Shachi’s MVR-based ZLD evaporators gained a lot of interest from visiting delegates. The Game-changing Self-cleaning Technology Maintenance, especially cleaning evaporators in wastewater treatment plants, was another big concern. Scaling and fouling of evaporators required frequent shutdowns for cleaning and reducing the plant’s life span. Shachi’s KLAREN Self-Cleaning Technology emerged as a game-changer. It reduces scaling and maintenance costs while providing consistent performance for weeks or months in a row. Need of the hour – a total solution! Several industries now realise the limitations of sourcing a wastewater solution in parts from multiple vendors. While reducing the capital cost will continue to be a priority, such plants have increased the Total Cost of Ownership, opined by several industry leaders. As a result, there is an increasing trend to source a solution from a single supplier to reduce complexities in integration, achieve reliable results, and better accountability towards the results of the technology. Shachi has always believed in offering a complete solution for specific industries with Stripper, Multi-Effect Evaporators, Centrifuge, ATFDs and Spray Dryers as per the process and effluent needs. Such comprehensive solutions were acknowledged to be economical, reliable, and efficient. Towards net zero – the shift is natural in the near future Many companies are considering sustainability in wastewater recovery as a financial investment in a renewable resource. When you invest in wastewater recovery, you’re essentially planting the seeds for long-term benefits. Sustainable wastewater practices yield multiple returns. They offer clean water for reuse and reduce the burden on water treatment facilities. Sustainability in wastewater recovery pays dividends in the form of both environmental preservation and economic savings over the long run. It’s a wise investment in our planet’s future and our financial well-being. IFAT 2023 was a milestone in marking the shift to sustainability with better economics. Shachi is geared for the change! #### Solving Today’s Water Challenges: Shachi Engineering at IFAT 2024 This October, Shachi Engineering will showcase its expertise at IFAT India 2024, which will be held from October 16 to 18, 2024, at the Bombay Exhibition Centre. IFAT India is the key event for businesses working in water, sewage, and waste management, bringing together the best solutions for sustainable industrial processes. Why IFAT India? IFAT India is where businesses and industry experts meet to explore new ideas for managing water and waste. Focusing on sustainable and efficient solutions, the event provides a platform for sharing knowledge, addressing environmental challenges, and discovering technologies that drive better resource management. What Shachi Brings to the Table At Shachi Engineering, we specialize in creating Zero Liquid Discharge (ZLD) systems and water management solutions designed for various industries. With 350+ projects across 10 countries, we’ve worked with 225+ clients, offering solutions that reduce waste and maximize resource recovery. Our focus is on practical, effective solutions that help industries improve processes, save water, and meet environmental standards. Visit Us at IFAT 2024 Meet us at Hall No 1, Stall A35, at IFAT India 2024, to explore how Shachi’s solutions can streamline your water and waste management processes. Whether you’re interested in improving efficiency or meeting compliance, we’re ready to discuss how we can support your business. One Place. Three Days. Endless Possibilities. #### Spray Cooler vs Beading Plant: 5 Key Differences Every Oleochemical Producer Should Know When it comes to solidifying molten fatty acids, glycerides, or waxes, two technologies dominate the discussion: the vertical Spray Cooler (also known as a spray-cooling Plant) and the horizontal Beading Plant. At first glance, both systems convert molten mass into solid particles but beneath the surface, they are engineered for very different operating needs. Here are five critical differences that every oleochemical producer should consider: 1. Particle Size & Shape A spray cooler atomizes molten mass through pressure nozzles into a cold air stream. The droplets solidify almost instantly, forming fine, powder-like particles typically between 100 and 1000 µm. Beading plants, particularly those engineered by Shachi, allow low-pressure droplets to fall from a precisely controlled height and velocity, enabling bead formation during the fall itself. This results in uniform, free-flowing with range tailored to customer requirements. (for ex: 750 µm +/- 150 µm). While powders pack densely, beads retain excellent flow properties even in humid environments. 2. Iodine-Value Flexibility Low iodine value (IV <2) oleochemicals are relatively easy to cool. High IV materials (>10), however, are more difficult to solidify due to their tendency to remain sticky. Spray coolers are well-suited for low-IV products, where single-stage air cooling is sufficient to stabilize structure. In contrast, beading plants utilize multi-stage cooling and optimized residence time, enabling them to efficiently handle a wide range of IV values from 1 to 20 broadening the scope of products that can be processed. 3. Cooling Stages Spray coolers operate on a single-stage cooling system, offering limited control over process parameters. Beading plants, on the other hand, feature two to three stages of cooling, giving operators full control over variables such as air inlet and outlet temperatures, melt temperature, airflow rates, and more. This level of precision ensures better process stability and product consistency. 4. Removal of Heat of Crystallization Spray coolers release crystallization heat rapidly in one air-cooling pass, producing fine powder that may require post-conditioning (e.g., silo ageing or open bag packing which lead to the delay in packing operation) to maintain flowability. Beading plants employ a sequential cooling process, often including a Integrated fluid-bed cooler (IFBC) and external vibratory fluidized bed cooler (VFBC) in the final stage. This gradual release of residual heat results in well-formed, consistently free-flowing beads straight off the line. 5. Automation & Footprint Spray coolers typically rely on basic automation with essential monitoring of process parameters. In contrast, beading plants offer advanced automation capabilities, including PLC-SCADA systems and IIoT integration, enabling recipe-driven control and real-time monitoring of all critical process variables. While there are many more points that bring of striking difference between a Spray Cooler and complete building plants. If want to know more about it just drop an email to marketing@shachiengg.com and our experts will get in touch with you. #### Spray Dryer atomizer systems How would chopping vegetables with a knife that has lost its edge affect the final dish? It will kill the consistency and texture of the dish. In spray dryers, atomizer system is much like a knife that needs to cut fluid particles precisely into finar parts, and if the automizer fails, it can have serious consequences. Atomization system works to chop up the liquid droplets into even finer droplets in order to serve the higher surface area to volume ratio. More the surface area available the greater will be the heat and mass transfer rate through droplet particle and this results in quick and effective drying process. An ideal atomiser is the one which provides the homogeneous spray i.e. symmetric uniform droplet size and shape, uniform residence time for all particle. Atomization systems are classified into two types: Rotary disk atomization In rotary atomization the feed is centrifugally accelerated to the high velocity before discharge in to the air. The liquid is allowed to flow over the rotating disk and this helps to attain both radial and tangential velocity component to the fluid. As a result, the liquid droplets of the fluid breaks into finer droplet particle as it leaves the rotating wheel. Pressure nozzle atomization Pressure nozzle accelerates and disintegrates the feed’s liquid flow. The droplet will be formed only when the feed’s liquid fluid disintegrates through the nozzle. For it to happen the pressure nozzle is designed with enough turbulence generation capacity. Spray Dryer Atomiser – What can go wrong and how it affects the product? In industrial application it is hard to achieve uniform droplet size which is dependent on many parameters such as flow rate, feed rate, sizing, properties of feedstock, powder properties, temperature etc. This makes the selection of right kind of atomization system even more complex. Also, an ideal automizer should not need frequent lubrication. Lubrication of the automizer system can sometimes lead to oil contamination of the final product. Many leading firms in the world are now introducing motors with magnetic bearings into the automizer to completely take out the need for lubrication. Shachi Enginering’s automizer design had development program is driven by insights and focused on delivering proven solutions. We provide in-detail investigation of process including the chamber., flow profile, and thermal analysis To know more about how our atomizations systems can help your business grow, get in touch with us at: Get in touch to know more #### Spray Dryer Ceramic Application Commissioned in Record Time Project Summary Location: Pune, Maharashtra Product: Spray Dryer (Skid-mounted) Evaporation Capacity: 25 kg/hr Application: Ceramic / Casting Sand Timeline: 1.5 months from concept to commissioning The Requirement A Pune-based client needed a compact solution of spray dryer for ceramic and casting sand. While the capacity was modest, the client had clear expectations: Consistent product quality Uniform particle size Compact footprint Fast execution within a short timeline Ability to handle inlet temperatures up to 450°C The Engineering Challenge The ask was simple, but the execution was not. The plant had to manage high temperatures, deliver a consistent product, and stay within space and time constraints. Shachi’s Solution Shachi delivered a counter-current spray dryer built on a compact skid. This helped reduce installation time while meeting all process requirements. Handled inlet temperature range of 420°C to 450°C Maintained uniform particle size across batches Compact skid-based design Delivered and commissioned in 1.5 months The Outcome The plant is now operational and meeting expected performance. The project highlights how smaller capacity systems, when engineered thoughtfully, can still meet demanding product requirements. Looking to build a compact drying plant around your application? Visit https://www.shachiengineering.com/ #### Spray Dryer Design – which is right for your process? What is the quickest and most efficient way of getting vast amounts of fluids to dry? That’s the central question dryer manufacturers battle with all the time. Thus, the best way to judge various types of dryers is by their qualitative and economical performance. Spray dryers are generally classified based on two criteria: The flow direction of hot air and feed, and flow loop of the system. Spray driers classified on basis of air and feed flow are designed to enhance thermal efficiency of the system. Which air flow is best suited for which process is determined by the properties of the material involved. There are three types of spray dryers based on air and feed flow direction. Co-current Flow In co-current spray dryer both feed spray and hot air flows in the same direction. This is one the most preferred designs, among all other flow designs in the spray dryer. Advantages of co-current flow include immediate expose of wetted droplet to the hottest gas available which results in quick initial drying and simultaneously rapid cooling of the drying air while minimising the probability of overheating. This arrangement is preferred even for the heat sensitive products. Counter Current Flow In Counter current spray dryers, the feed and hot air are sprayed in opposite direction and dried particle comes in a contact with hottest air. Counter current flow system is more energy efficient as compared to the co-current system. Typically, minerals, soap, detergent etc. are produced with the counter current spray drying system. Mixed Flow The mixed flow is a combined type of Spray Dryer with both co-current flow and counter current flow system. In this type, hot air is drawn from top of the drying chamber and feed spray is located at the center of the chamber. The mixed flow type of systems are typically used for products which require relatively higher residence time in the system. Experts advise running on-site tests on material to determine which system would be best suited for drying. Shachi engineering has the expertise to help you choose the right kind of system that allows you to arrive at the desired solution and performance quickly. CFD calculations are used to determine the most optimal flow and narrow down on the right model of spray dryer. Get in touch to know more #### Spray Dryer Design: Simple in Appearance, Complex in Reality At first glance, a spray dryer machine seems straightforward liquid goes in, powder comes out. This simplicity, however, is a myth. In reality, spray drying is a highly engineered process where multiple variables must work together to deliver consistent, saleable powder. The spray dryer principle is based on atomizing liquid feed into fine droplets and drying them instantly using hot air. But the success of this principle depends heavily on understanding the nature of the product, feed properties, ambient conditions, and site-specific constraints. Ignoring these factors often leads to common but costly problems, including sticky product, wall deposition, lump formation, over-drying, browning, charring, and excessive energy consumption. The Right Spray Dryer design Process is the key A well-designed spray dryer process considers feed solids, viscosity, heat sensitivity, and hygroscopic behavior. It also accounts for atmospheric conditions such as humidity and temperature at the client’s location, which directly impact drying behavior and powder stability. When these elements are overlooked, powders may stick to chamber walls or ducts, cyclones may underperform, and operating costs rise sharply. Spray Dryer Machine Design is the Skill In practice, spray drying is not just equipment selection, it is a balance of science, engineering, and experience. It requires precise design of atomization, airflow, residence time, and thermal profile to protect product quality while ensuring efficient operation. That’s why spray drying is best handled by specialists. When designed correctly, a spray dryer delivers uniform particle size, controlled moisture, stable flowability, and predictable energy use batch after batch. #### Spray Dryer History We generally like to forget moments when we end up with an egg on our face, but here is a story where eggs kickstarted a journey that would change the world. The earliest mention of spray drying involved egg-handling in 1865. But pride of place must go to a Mr Samuel Percy, who is considered the first to have described in detail the spray drying of product in spray form. His patent of 1872, entitled ‘Improvements in drying and concentrating liquid substance by atomizing contains no diagram; But the idea was clearly laid out in the words: The invention is a process of atomizing the desiccating fluid and solid substances, which differ from the ordinary atomizing apparatus in so much that the air or gas which forces the substance into atoms is dried, heated or cooled and also thrown forward forced into chamber and dried in consequence of the dried or heated air which propels them into chamber. Industrial application of spray drying at any significant scale first occurred in the milk and detergent industries, in the 1920s. Till that could be done, spray drying had to evolve over a period of many decades from 1870 to early 1900s. Spray drying process witnessed widespread use and evolution during world war II when ways were needed to reduce weight of food material so that it could be transported quickly. Since its origins, spray drying has come a long way in terms on advancement as well as output. The world’s biggest spray dryer was put into operation in 2013 in New Zealand. It can produce 30 tonnes of milk powder an hour. The global market for spray drying equipment was valued at around $ 4.11 billion, and is projected to reach $ 6.12 billion by 2023. The next step in the evolutionary story of dryers would probably witness the interaction between Artificial Intelligence and CFD technology which is used to a large extent in spray drying. Get in touch to know more #### Spray Dryer Installation for a German Client Product (Client): A leading German MNC based in Bangalore specializing in high-quality ceramics manufacturing. Timeline: The plant has been operating at full capacity for over 1 year. Status of the Plant: The plant is functioning efficiently and consistently, meeting the client’s critical specifications. Plant Capacity: The installed spray dryer handles 102 kg/hr of water evaporation, processing high solid-content slurry (~70%). Project/Equipment (Shachi): Spray Dryer with Open Cycle Rotary Atomizer Summary of the Project: The project involved designing and commissioning a spray dryer for ceramic applications, focusing on producing high-quality alumina ceramics. The goal was to achieve specific particle size distribution with precise moisture content in the final product while handling high solid-content slurry feeds. Challenges in the Project: Particle Size Requirement: The client needed a specific particle size for the ceramics. High Solid Content Feed: Managing slurry feeds with over 70% solid content posed significant challenges in terms of drying efficiency. Atomization: Achieving the required atomization was critical due to the high viscosity of the slurry. Moisture Control: Maintaining moisture content below 0.1% in the final product was another key challenge. Loss of Ignition: To meet the quality standards of the ceramic materials, the client required precise control over the loss of ignition (LOI). Bulk Density: Achieving the correct bulk density of the final product was essential to ensure consistency and quality in ceramic production. Solutions by Shachi: Customized Design: Shachi engineered a bespoke spray dryer with a specialized feed and pumping system capable of handling high-solid content slurries. Rotary Atomizer: A high-speed rotary atomizer was imported from Italy, designed specifically for this application, ensuring precise atomization without the need for oil lubrication. Moisture Control: Shachi employed advanced moisture control through optimized plant mass balance and temperature management, ensuring consistent moisture levels below 0.1%. Oil-Free Operation: The atomizer design was customized to ensure oil-free functioning, eliminating the need for lubrication oil while meeting strict client standards. Looking for customized drying solutions that ensure precise particle size and moisture control? Contact Shachi Engineering today! Additional Points: The plant’s performance has been consistent, operating at full capacity for the last year. Shachi’s collaboration with European partners ensured the integration of top-tier rotary atomizers, contributing to the plant’s success. #### Spray Dryer Maintenance Spray Dryer Maintenance – Deposition problem in the dryer chamber and how to counter it If you pay for a full glass of milk and receive only about 3/4, you know there is a problem. Food and pharmaceutical industry has been battling the same problem over the past many years, and the core of this problem lies a single most vital component in spray drying system: The drying chamber. When a huge industrial spray dryer is producing milk powder of around 28 tones per hour, the potential loss caused due to product being deposited on walls of drying chamber is immense. Thus, avoiding the problem of wall deposition forms the backbone of a quality drying chamber design. Spray Dryer Deposition Cleaning Large amount of deposition makes it difficult for the dryer to operate smoothly. Thus, downtime taken in cleanup operations causes further loss of production time. Additionally, in some cases, deposition can also cause or elevate the risks of fire hazard. Researchers have previously tried using nylon walls to reduce deposition, but that did not work. One key solution of this problem is to predict the particle flow pattern using CFD technology. Shachi Engineering uses advanced simulation and technology (CFD) to predict the internal flow field of spray chamber from which ejected droplet and track this information to reduce or eliminate deposition and deliver better end products. Get in touch to know more #### Spray dryer process flow Quantity and quality are generally perceived to be on the opposite ends of the spectrum, and it is believed that if you chose one, you must compromise with the other. However, spray drying is one sector that must always deliver the precise size of particles in large amounts. Both quality and quantity matter in spray drying., Spray drying technology turns liquids into powders that have specific particle size and moisture content. Spray drying can be used to dry both kind of materials: those that are heat sensitive, and those that are heat resistant. Spray drying uses gas as a medium to quickly dry liquids, and it works in four stages: Feed Preparation and Concentration Feedstock preparation is performed prior to introduction of the feed in the spray chamber. Concentration of feed solution is achieved to ensure it can be pumped to chamber. Sometime, the feedstock is heated to alter the physical property of the feed solution. Atomization Spray drying is mainly characterized by atomization of the feedstock. Atomization involves separating the fluids or slurries into fine particles. The Atomisation process breaks-up bulk liquids into droplets. Atomised fluid serves the optimum condition for the moisture to evaporate in a quick and effective way. Atomization of feedstock can be achieved either by rotary atomization or by pressure nozzle. The Dryer can include single to multiple nozzle systems, as per the process design. Droplet-air contactor How the heating medium i.e. hot air and droplet is contacted is at the heart of overall drying process. In the chamber hot air is drawn through the inlet in specified flow pattern, called air distributor and brought to the droplet which need to be dried. The way through which the hot air and droplet is contacted decides the size, quality and texture of the dried product. The type of the contact between air and droplet is decided by the product quality and position of the atomiser or nozzles. Droplet Drying In the process of moisture removal or evaporation is performed in stages. These stages generally referred to as constant rate drying and falling rate drying. In first stage of the drying, sufficient moisture content is available in the droplet which is ready to evaporate at constant rate. In secondary stage moisture exerts more resistance, compared to the first stage, to evaporate against the hot air and thus process of evaporation slows down results into falling rate of drying. The additional resistance provided in the secondary stage depends on the physical and chemical property of the feed and pore structure of the solid-droplet. Separation Following complete evaporation of the moisture content from slurry droplet, solids are to be dried in the particulate form and need to be separated from drying medium i.e. hot air and drying chamber. Separation equipment provided after the drying chamber helps to achieve the same. Cyclone separator, wet scrubber, bag filter and electrostatic separator is provided to ensure complete recovery of dried product and to ensure exhaust gas does not contain any environment damaging particulate matter so that air can be safely released in to the environment. Considering the critical nature of drying, the design and installation of dryers needs skill and experience. At Shachi engineering, we emphasize establish advance simulation and analysis using Computational Fluid Dynamics (CFD) techniques. Our team has many years of expertise in designing of spray dryer with optimum performance and successful delivery of 500+ plant with promised features. To know more about how our spray driers could help your business grow, get in touch with us. Get in touch to know more #### Spray Dryer Process for Flavours in Food and Cosmetics Production of dry flavorings is achieved easily with spray drying. The Spray Drying process involves an aqueous feed material which includes water, carrier, and the flavor is atomized into a stream of hot air. The atomized articles tend to dry rapidly. The volatile flavor constituents is trapped inside the droplets. The powder is sometimes recovered via cyclone collectors. Choosing the right operating parameters is critical to flavor retention. Since spray drying technique is equally good in handling of both water soluble and oil-soluble flavor systems, it continues to be the preferred encapsulation process. It is also relatively cost effective and can be easily scaled from pilot plant to the commercial production. Spray Dryer Factors Flavor encapsulation employing the spray drying process involves a large number of interactive factors. These include: the flavor, the flavor cosolvent, the carrier composition, the emulsion solids-to-water ratio, emulsion preparation and lipid particle size distribution, as well as the dryer system and the operational drying conditions. Formulated flavour is the first step in encapsulation process. Flavour chemicals have a tendency to vary in water and oil with respect to their Volatility and chemical reactivity. Spray Dryer Carrier The carrier composition is the most critical component in the spray dry encapsulation system. The preferred carrier material should dissolve easily. The material should ideally be water-soluble, bland, inexpensive, have excellent oil-emulsifying and droplet stabilizing properties, exhibit low solution viscosities at higher dissolved solids levels, have excellent film-forming properties, dry easily and form a glassy amorphous powder upon drying. No single material meets all of these criteria. Carrier systems are usually formulated by combining a number of water-soluble components. The first of these components are the water-soluble polymers. The plant based materials have the advantage of being natural, providing excellent emulsifying and film-forming properties while exhibiting relatively low solution viscosities even at 35–40% dissolved solids in solution. On the negative side, they suffer from large swings in ingredient cost, as well as quality and availability issues. Spray Dryer Process A general schematic of a spray dryer is shown below. The spray drying process can be broken down into a number of operational steps. These include preparation of aqueous carrier phase; emulsification or solubilization of the flavor; delivery of the emulsion/flavor as a fine particle stream into the dryer; and drying under controlled rates and drying temperatures to obtain the product—a dried encapsulated flavor particulate. The flavor emulsion is prepared by first dissolving the carrier in the mixing tank The flavor is added and the emulsion generated by passage of the flavor through a homogenizing unit which is then fed into a surge tank. This flavor emulsion is metered into the drying chamber that has a preheated hot air stream, set at a predetermined temperature. The liquid flavor-carrier emulsion droplets are dispersed by the centrifugal head atomizer (or nozzle atomizer) into the heated air within the chamber plenum at a specific rate. The droplets are almost instantaneously heated to 100°C. Each liquid droplet rapidly gives up moisture at the air-liquid interface forming a film on the outer droplet surface. Water molecules rapidly diffuse out of the droplet, increasing the solids content of the particle as it dries. Evaporative cooling protects the flavor and the increasing solids retain the entrapped aromatic flavor molecules. By balancing the air-outlet temperature with air-inlet temperature by the liquid feed rates, the particles can be held at 100°C—the wet bulb temperature—during the full drying process. Ultimately, the fully dried particles are swept out of the chamber into the cyclone and collected in the receiving chamber. The recovered encapsulated flavor-carrier matrix will be an amorphous solid and based upon the carrier composition and drying dynamics; the solid should be in the desired glassy state. The choice of the carrier will be made from a carrier library developed and optimized for specific flavor systems. These and a number of potential encapsulation options can be explored if the flavorist and encapsulation specialist leverage their understanding of the physical chemistry of flavor-carrier-drying interactions and dynamics. However, for routine spray drying of most flavors, understanding the principals of the spray drying encapsulation process and utilizing selected carriers and process conditions will ensure a flavor can be delivered in a quality manner. Encapsulated flavours have many advantages: Easier to handle Spray drying offers protection that will slow down degradation and extend the shelf-life of the product Spray drying protects flavours from exposure to oxygen and enables the retention of more volatile ingredients Some popular spray dried flavour taste profiles where Shachi Engineering has proven technology includes Citric Flavours, Fruit Flavours, Vegetable Flavours, Herbs and Spices, Coffee, Chocolate and Caramel Get in touch to know more #### Spray Dryer Process: Its utility and purpose How do you produce 28 tonnes of milk powder in just one hour? In drying perishable and sensitive materials in industries such as food or pharmaceuticals, speed is the key. That’s something that only spray drying can achieve. So how does spray drying get you so much speed and efficiency? Spray Dryer Working Here’s how a Spray Dryer works: Spray drying process which can dry huge volumes of liquids within seconds is thus critical in this area. Manufacturing of products such as milk powder in large quantities is only possible because of spray drying process. Spray drying produces particles that can be dispensed fast and are easily soluble. Spray drying technology offers several features over its preceding technologies. Spray dryers turn a liquid into a powder by quickly drying it with help of hot gas. The one-step ability of Spray Dryers to complete the drying process within seconds gives it an edge over most other industrial drying techniques. For instance, in the food industry, fast drying plays a vital role in ensuring minimum overall flavour loss. The process operates on basic principles and can be automated at several levels. The process is versatile and adaptable to a wide range of industries and their feedstock and product specifications. Virtually any feedstock that can be pumped – solutions, suspensions, slurries, melts, pastes, gels can be spray dried. Spray Dryer Efficiency Designing efficient and cost effective spray dryers though requires skill and experience. In spite of all the engineering advances in spray drying technology, achieving the right results through a Spray Dryer is a science as well as an art. Procedures for specifying and designing of spray dryers varies significantly, based on the experience, theoretical approaches and empirical methods. The prediction of perfect drying design is difficult due to the inability to express precisely the interaction of spray droplet and air around the atomizer and the resultant particle and air flow pattern in the drying chamber Spray Dryer Manufacturer in Pune and Gujarat At Shachi Engineering, we create detailed simulation of interaction between gas and fluid using Computational Fluid Dynamics technology. This, in addition with the company’s two decade-long experience in designing dryers helps us deliver the most efficient and cost effective dryers. To know more about how our dryers could aid your business growth, reach out to us at: http://www.shachiengineering.com Get in touch to know more #### Spray Dryer technology to improve your product quality Spray Dryer – Technology and Art! Spray Dryer is both art and technology. The technique transforms a fluid body into a dry powder/granule form using an atomization process inside a heated chamber. The reduction of the wet slurry into small individual droplets is called Atomisation. With sufficient retention time inside the spray dryer chamber, the water evaporation continues until the desired moisture content is obtained. Several factors are involved in setting up the drying process. The final target moisture is the most fundamental factor. Other factors include the color, flavor, particle size, bulk density and flow properties. The end product qualities are very important depending on the application. For example, in case of a beverage the ability of the powder to sink and disperse in water is decisive to the success. Achieving results from Spray Dryers While the spray dryer fundamentals may seem simple, a lot of planning is required to achieve the right results in terms of formulation. The end powder formula to be achieved has a huge impact when it comes to the design of the drying conditions. In food and beverage it means, for example, a low density verses a high density powder, a low fat verses a high fat powder, a low protein verses a high protein product. The designs may differ based on whether the powder will be used in a dry mix or in a mixed in a hot liquid or will flavor a cold beverage. The emulsified powder should be able to to retain its integrity and properties in the target pH environment where its ultimately used. For products such as dyes, it is important to consider if environmental characteristics that need to be considered in the design of the product. Factors such as hydration rates, relative particle size must be considered in order to provide necessary overruns. Drying considerations also include slurry feed, the type of atomizer nozzle and its configuration, air supply system, heating conditions, and transport for packaging. Spray Dryer Conditions Plant trials are the litmus test and must be conducted prior to introducing a powder formulation in a plant environment. The pilot plant study will help to establish and validate the spray dryer conditions. The parameters help to gain a better understanding of the behavior of various elements such as slurry solids, process or inlet outlet temperatures, feed drying rates, moisture content changes and the bulk density. The powder produced in the pilot plant can then be tested for performance attributes that are desired in the application of the product. Shachi Engineering has a full scale pilot plant in Pune, India that includes spray drying capabilities for production of small scale samples for customer evaluation prior to scale up to production. What are Your Spray Drying Needs? Please contact our representative to discuss product development efforts. Our sales team and Technical Staff can assist you in the design of a powder for any of your customized applications. Get in touch to know more #### Spray drying plant with advanced PLC control systems For one of the maharatna company in India, Shachi Engineering has specially designed and manufactured the skid mounted spray drying plant. This plant will be an integral part of their crucial Research & Development project. This specially designed continuous operation spray drying plant is equipped with advanced PLC control systems, making it easy to operate. In addition to it, our spray drying plant offers low maintenance and high production efficiency. The unique CFD technology helps to analyse the fluid flow pattern inside the spray drying chamber and support to optimise the process efficiency. Get in touch to know more #### Suruchi Shanbhag gets honored with Engineering Excellence Award Shachi Engineering, a leading industrial drying and evaporation solutions provider, is proud to announce that our CEO, Suruchi Shanbhag has been recognized with the prestigious “Engineering Excellence Award” during the award ceremony on 26 May 2023 at Tip Top International Hotel, Pune. This distinguished accolade is a testament to Suruchi’s exceptional leadership, innovative vision, and remarkable contributions to the field of engineering. The Engineering Excellence Award is a highly coveted honor bestowed upon individuals who have demonstrated exceptional expertise and achievements in the engineering industry. Suruchi’s relentless pursuit of excellence, coupled with her deep understanding of cutting-edge technologies, has propelled Shachi Engineering to the forefront of innovation. Under her guidance, Shachi Engineering has consistently delivered ground-breaking solutions and surpassed industry standards. Her strategic foresight and ability to inspire and motivate teams have fostered a culture of innovation and collaboration within the organization. As a result, Shachi Engineering has achieved numerous milestones. While commenting on this occasion, Suruchi Shanbhag said, “I am deeply honored to receive the Engineering Excellence Award. This recognition is a testament to the exceptional talent and dedication of our entire team. I am grateful for their unwavering support, as well as the trust and confidence of our valued clients and partners.” Engineering excellence awards event was organised by Divya Media. Divya Media has been in the business of publishing technical magazines and organising industry events since past 25 years. The committee of jury members from various reputed companies selected the winners after scrutinising each nominee on various parameters. The Engineering Excellence Award is yet another milestone in Suruchi’s career, which is characterized by a passion for innovation, a commitment to excellence, and a relentless drive to push the boundaries of engineering possibilities. This recognition serves as an inspiration to aspiring engineers and a testament to the remarkable achievements of Shachi Engineering. Media Contact: Sandeep Jadhav Marketing Manager Shachi Engineering Pvt. Ltd. M: +91 7030470246    E: sandeep.jadhav@shachiengg.com #### System flow loops of spray dryers Explosives and pharmaceutical products are some of the sensitive materials that undergo spray drying process. Similarly, environmental concerns too deeply influence the design and working of spray dryers. Modifications are made to the flow loop system to tackle sensitive products and reduce the environmental impact of spray drying process. Spray dryers are classified in three different types on the basis of the flow loop system: Open cycle In open cycle drying system air is drawn from the surrounding, heated and used as dying medium and after its utilisation it is then released to the environment. This type of system commonly used when moisture content in the feed is water. Picture: Open Cycle Co-Current Flow System ⦁ Air suction from the surrounding ⦁ Air heater ⦁ Feed ⦁ Drying chamber ⦁ Cyclone separator ⦁ Powdered product to packaging ⦁ Venturi scrubber ⦁ Scrubber tank ⦁ Exhaust duct/Vent to the environment Closed cycle In the closed loop cycle, the drying medium is heated and utilised to remove solvent from the feed spray; condensed further to remove moisture content and then reused again as the drying medium. The Closed Cycle system is used when moisture content is valuable or hazardous and therefore needs to recovered. Spray Dryers for flammable, toxic or explosive products or Pharmaceutical products/intermediates which need to be produced in sterilized conditions typically use a closed cycle loop type systems. Picture: Closed Cycle Co-Current Flow System ⦁ Air suction ⦁ Indirect air heater ⦁ Feed ⦁ Drying chamber ⦁ Cyclone separator ⦁ Powdered product to packaging ⦁ Venturi scrubber ⦁ Scrubber tank ⦁ Exhaust duct ⦁ Moisture removing equipment ⦁ Coolant ⦁ Condensate ⦁ Hot air Semi closed cycle This system lies rests in between open cycle and closed cycle. This type of arrangement is used to utilise the exhaust heat that leaves the drying system. This adjustment reduces the fuel consumption or overall energy load on the system. Picture: Closed Cycle Co-Current Flow System ⦁ Air suction ⦁ Air heater ⦁ Feed ⦁ Drying chamber ⦁ Cyclone separator ⦁ Powdered product to packaging ⦁ Venturi scrubber ⦁ Scrubber tank ⦁ Exhaust duct ⦁ Moisture removing equipment ⦁ Coolant ⦁ Condensate ⦁ Air bleed to atmosphere ⦁ Fuel gas At Shachi, we sense the vital role of spray-air interaction and particle-air movement very important aspect of design. And single procedure of estimation is never really universally applicable in the drying process as with every product that is being dried there is bound to be a variation in plant capacity, variation in atomizer design, temperature and feed location. Considering each dimension of the complexity and difficulty of the drying problem the team of experts at Shachi Engineering has established advance simulation and analysis using Computational Fluid Dynamics (CFD) techniques. Our team has many years of expertise in designing of spray dryer with optimum performance and successful delivery of 500+ plants with promised features. Get in touch to know more #### Two Sides of Sustainability Sustainability is a term that resonates with us all, emphasizing the importance of recycling, reusing, and reducing our environmental impact. This is undeniably a critical aspect of sustainability, but another often overlooked dimension is the sustainability of the systems and solutions that enable us to protect the environment. In various industries, especially in areas like wastewater treatment, the sustainability of Effluent Treatment Plants and Zero Liquid Discharge (ZLD) systems is a pressing concern. These systems are integral to treating industrial effluents and wastewater, safeguarding our environment, and conserving precious water resources. However, they come with their challenges, primarily related to high operating costs. At Shachi Engineering, we recognize the need to address both sides of sustainability. Our approach to sustainability extends beyond designing and implementing solutions that protect the environment. We ensure that these systems are not only environmentally friendly but also economically viable and built to withstand the test of time. Practical Solutions for Environmental Protection In today’s world, we have access to innovative solutions designed to treat industrial effluents and wastewater effectively, significantly contributing to reducing pollution and conserving water resources. When implemented correctly, they help industries minimize their environmental footprint, resulting in cleaner waterways and greener surroundings near industries that use these systems effectively. The Challenge of Proper Implementation and Maintenance However, there’s another side to this story. In some instances, industries don’t utilize these solutions as intended. This can range from inadequate treatment of effluents to neglecting the maintenance of critical systems. The consequences can be severe, resulting in rusty machinery, neglected facilities, and contaminated water bodies. This neglect not only harms the environment but also tarnishes the reputation of industries as responsible corporate citizens. This highlights that sustainability is not just about the solutions themselves but also how they are used and maintained. Shachi Engineering’s Role in Ensuring True Sustainability This is where Shachi Engineering plays a vital role. We provide sustainable solutions to our clients by not only designing and implementing these systems but also by ensuring they are maintained, optimized, and used to their full potential. Our dedicated teams work diligently to monitor processes, collaborate with industry leaders, and ensure that these solutions are not just a one-time implementation but a continuous commitment to sustainability. We believe in transparency, efficiency, and proper system management during audits and daily. The Two Sides of Sustainability In the world of sustainability, there are indeed two sides. On one side, there are practical solutions that protect our environment and conserve resources. On the other side, there is the challenge of proper system management and utilization. At Shachi Engineering, we strive to ensure that the side that matters most is the one where we protect our environment, conserve resources, and promote a cleaner, brighter future for all. We believe that sustainability is not just a buzzword but a responsibility that we must fulfil for the well-being of our planet and future generations. #### Understanding Spray Cooler | Beading Plant | Spray Congealing for Fatty Acid Processing Spray congealing is a continuous process that converts molten materials into uniform granules through rapid cooling. In the oleochemical industry, it’s commonly used to solidify fatty acids like stearic and palmitic acid into stable, free-flowing products. How Spray Cooler | Beading Plant | Spray Congealing Works A specially designed spray nozzle is used to atomize molten feed into a cold air chamber. Upon contact with cold air, the droplets lose heat and solidify mid-air, and bead formation takes place. The solidified particles are collected through a fluidized bed cooler to stabilize bead/particle temperature and structure. Why It’s Ideal for Oleochemicals, Fatty Acids, Waxes, Esters, etc. Fatty acid processing requires strict control over: Granule size distribution (typically in the range of 300–1000 microns) Iodine Value (IV) variation (IV range: 1 to 20) Minimization of fines and lump formation Automation for better operational control and reliability of the plant with the PLC-SCADA system Spray Cooler/ Beading Plant/ Spray Congealing provides uniformity and flowability, which are critical for packaging, downstream dosing, and thermal stability. Shachi’s Engineering Approach Shachi designs Spray Cooler/ Beading Plant/ Spray Congealing plants based on: Thermal profile of the specific fatty acid Special In-house Nozzle Design for uniform particle size distribution Product loading rate considering melting, feed, and required product temperature Strict control of feed and product temperature Multi-stage cooling for high Iodine Value (IV) Application Air Cooling through an evaporative cooler or chiller radiators, based on product requirement Plant footprint and layout requirements Plant design to operate on open & closed loop configuration Each plant is complex, customized, and built for easy installation and consistent, long-term, guaranteed performance. Need a Spray Cooler| Beading Plant| Spray Congealing Setup for Oleochemicals| Fatty Acids? We build systems mapped to your product’s particle size requirement, High IV feed operations, cooling profile, and flow characteristics. Talk to our team atshachiengineering.com #### We are soon going to be in Dahej! Shachi Engineering recently acquired land in Dahej to expand its manufacturing facility. Currently, Shachi Engineering has a state-of-the-art manufacturing plant in Pune. The facility in Pune is also equipped with a pilot plant and has been pivotal in Shachi Engineering’s growth. With the facility at Dahej, Shachi Engineering will now be able to serve larger projects at more aggressive timelines. The 2.5 Acre land near Saika Chemical SEZ in Dahej is located strategically to serve the growing needs for quality process plants, especially in Gujarat. The facility will help expand Shachi Engineering’s manufacturing output by about 40%, in addition to serving the customers faster. Greenfied facility to serve larger projects Additionally, Shachi Engineering also plans to begin serving customers from new segments such as Oil & Gas, Speciality Chemicals and Pharma, from the new expansion. The facility will focus on manufacturing larger capacity Evaporators and Condensors and will be key to driving Shachi Engineering’s growth in the western India region. #### What drives you to work every day? ….our employees have one more reason! There are two types of office goers. The passionate and enthusiastic ones, who are always looking ahead to go and contribute. And there are a few who make it to the office out of compulsion of sorts. The difference is between the connection they have to the work and the workplace. Recognizing the efforts of our top performers At Shachi Engineering, we focus a lot on connecting the dots between the individual’s dream and the organization’s vision. From the start, we have seen that when people see and feel that connection, passion and energy flow to work naturally. We have seen the employees feeling an elevated sense of dignity, importance and new energy to drive to work, every day. And to make that happen, we have given our employees one more reason. We are pleased to announce that this year 5 of our long-standing employees have been offered company sponsored brand new Cars as a recognition of their contribution. For all the employees, which also includes two Workers, it was always a dream to own a car. And as an organisation, we are proud to have helped them to achieve their dream. One more way to say that our people are our strength. #### When a chance visit led to transformation of business! Transforming from sub-optimal to optimum GACL is a forward-looking company, set up in the year 1973. With an initial capacity of 37,425 TPA Caustic Soda, GACL has grown to be one of the largest producer in India, with a capacity of 4,29,050 TPA. GACL’s plants are spread over 2 complexes at Vadodara and Dahej. In a chance meeting with the officials of GACL, who at that time were concerned with the pollution caused by PAC ( Poly-aluminium Chloride) and CaCl2, Shachi Engineering’s MD, Mr. Shanbhag, offered to help to solve the problems. The officials opened up the records of the plant and showed the current state. While the plant was relatively old, it was troubled with a sub-optimal performance at several levels. Challenge Pollution levels PAC and CaCl2 are highly hygroscopic materials. Back then, the pollution levels at the plant were very high, often leading to a slimy floors and road outside due to leakages from the Plant. Near Zero results Living with the level of pollution had become a norm for the internal team, as all their efforts to arrest the situation had yielded little or no results. Solutions Shachi Engineering’s team stepped in to study the process, materials and critical paths in the existing systems. Senior personnel from Shachi Engineering and the Managing Director visited the plant before suggesting the solution. Upon an in-depth analysis, Shachi Engineering suggested modifications in the scrubbing system, cyclones and the existing conveying system of the plant. This was delivered with a guarantee to improve the fuel consumption efficiency at the plant as well as reduce the emmissions. Results The modifications suggested and delivered by Shachi Engineering’s team brought about a significant and immediate improvement in the pollution control as well as the overall performance of the plant. The leakage of the PAC and CaCl2 was arrested and with improved processing Delevering solution in record time The problems of slimy floors and roads was not to be seen anymore #### Why Do ZLDs Underperform? Uncovering the Truth Behind Water Recovery Challenges Zero Liquid Discharge (ZLD) systems are designed to help industries recover water and meet compliance targets, all while minimizing environmental impact. But here’s the catch—many ZLD plants don’t perform as expected, often resulting in higher costs and unstable operations. What’s going wrong? It’s often not the technology itself, but the design and implementation process. Too often, we focus on the theory of ZLD, without addressing the real-world complexities that affect performance. The Myths About ZLD ZLD may seem straightforward: recover water, and eliminate discharge. However, several challenges remain. From fluctuating feed conditions, scaling issues, fouling, and improper pretreatment to inefficient heat integration—many factors contribute to why your ZLD system might underperform. The Truth Behind ZLD’s Underperformance One of the key reasons for ZLD underperformance is variability—in both the quality and volume of effluent streams. When the influent changes from one batch to another, or even seasonally, the system can’t adapt quickly enough. This unpredictability creates operational imbalances leading to higher energy consumption, longer treatment cycles, and a compromised recovery rate. Another challenge lies in pretreatment. Without proper pH stabilization and solids management, the efficiency of the downstream treatment units like membranes and evaporators diminishes drastically. It’s the basic building blocks that make the entire ZLD system successful, and skipping steps can lead to wasted energy and missed recovery targets. How to Fix It The good news? You can fix these issues by fine-tuning your design and operation. With a comprehensive audit of your plant’s water balance, chemistry, and fouling index, Shachi’s team helps ensure that every aspect of your ZLD system is optimized. From pretreatment tweaks and membrane staging to evaporator selection and heat integration, we map out the right solution that suits your plant’s specific needs. This ensures stable quality, lower OPEX, and a faster payback. The Bottom Line ZLD systems, when designed and maintained correctly, can deliver huge benefits—such as reduced water consumption and compliance with environmental regulations. However, it’s critical to understand that ZLD isn’t a “one-size-fits-all” solution. It requires a tailored, adaptable approach to meet the real-world challenges that affect its efficiency and performance. Want to ensure your ZLD works at its peak? Share your data with us, and we’ll map a solution that fits your site’s specific needs and recovery targets. #### Why Particle Size Matters! How Shachi delivers exact particle sizes Open any bag of powder, may it be nutraceutical premix, food ingredient or detergent base -and one trait quietly decides how it pours, packs, dissolves, and sells: particle size band. Too fine and you get dust, caking, and slow packing. You get coarse and lose dispersibility and consistency. That’s why, in spray drying, size isn’t a by-product of design; it is actually way around, particle size decides Spray Dryer design. Why particle size matters to your business Customer experience: Flowability, dust levels and how fast it reconstitutes in water all track back to particle size. Packaging & logistics: The right bulk density reduces bag count, stack height and transport loss. Price realization: Buyers often specify size bands. Hit them reliably and you avoid discounts, rework or claims. How size drives the dryer you choose At Shachi, we start every project by fixing the target particle size and distribution then engineer backward. Number of drying stages: Finer powders typically suit single-stage drying. If the need is of larger, free-flowing particle size band, we add an integrated or external fluid-bed stage to finish drying and shape the granule. Product density & feel: By tuning the percentage of fines recycle (sending light particles back into the chamber) we can build structure, raise bulk density and cut dust. Air contact & residence time: Co-current vs mixed flow affects how quickly a droplet dry, which in turn sets surface texture and hollowness, key to dissolving performance. Atomization strategy: Pressure influences initial droplet size, nozzle selection strategy is defined on desired μm (micron) sizes. The Shachi way: size-first, proof-backed Size Briefing: We align on commercial targets (e.g., D50/D90 bands, bulk density, moisture). This becomes the spec sheet the plant is built to serve. Pilot trials: In our application setup we run compact trials varying atomization pressure, inlet/outlet temperatures and recycle rate to map how size responds. CFD validation: We run CFD simulations to visualize airflow and droplet paths inside the chamber, spotting hot/cold zones, fine build-up risks and uneven residence times. So the plant hits the size band more reliably. Configuration mapping: Results guide the stage count, recycle arrangement and airflow strategy. If your market needs bigger, rounder particles, we incorporate fluid-bed finishing. Scale-up with confidence: We transfer pilot learnings to plant scale with documented set-points, so you reach saleable powder faster. Particle size band is the lever that links performance in your customer’s hands to efficiency in your plant. By designing the spray dryer around your size target stage count, recycle, airflow, and controls, Shachi helps you land the powder your market values at the cost your P&L needs. Have a product in mind? Share your desired particle size band and density. We’ll map the configuration and prove it in trials #### World Environment Day – 2025 Stand behind almost any factory and you’ll find it.A quiet stream of grey water snaked behind the building. Warm, slow-moving, sometimes foaming. Sometimes there’s a drain. Sometimes it just flows into the soil. No warning board. No sense of where it’s going. But it always goes somewhere. This is what untreated industrial wastewater looks like. It’s not rare, it’s not distant. It happens every day in thousands of plants across every central manufacturing zone in the country.And it doesn’t disappear. It enters canals, rivers, lakes, crop fields, and groundwater. The scale of untreated discharge India generates massive volumes of industrial wastewater every single day. Yet only a small portion of it is ever treated properly. The rest either seeps out or gets diluted and released. This is not because we lack the technology but because treatment systems are often underdesigned, oversized, or neglected.This untreated water contains more than colour or odour. It also contains heavy metals, solvents, high salts, and long-term damage. Why do treatment systems often fail? Most industrial treatment plants are designed once and left untouched for years. The effluent chemistry changes in many cases, but the system doesn’t. In others, the evaporators choke every few days. Operators override settings. Discharge valves are opened in an emergency. Compliance becomes a formality. It’s not just about having a ZLD system. It’s about having one that works with the actual effluent a plant generates, not just the one in the datasheet. What a working ZLD system actually looks like A functioning zero liquid discharge system isn’t just a combination of RO, evaporator, and crystallizer. It’s a process designed to recover water without constant breakdown.That means: Pre-treatment that matches the hardness of your feed RO systems sized for your real recovery goals Evaporators that don’t need cleaning every 72 hours Solid-handling systems that don’t block flow Controls that are easy to operate, not just to showcase One of the biggest gaps in traditional setups is the evaporator. Most ZLD failures are due to poor evaporator design or maintenance. Why does this matter more now than ever? Water reuse is no longer a branding move. Raw water costs are climbing. Audits are stricter.Buyers, especially those from global markets, are beginning to track environmental data in the same way they track pricing. For many sectors, ZLD is no longer optional. It is the only way to avoid supply chain risks, production halts, or regulatory suspension. This Environment Day, the challenge isn’t distant. It’s behind your plant. Sustainability doesn’t begin with a pledge. It starts with a pipe. And that pipe is either helping or harming. There is no neutral ground anymore. The theme of World Environment Day often focuses on forests, oceans, or air. But for industries, it starts with water. What you take, how much you use, and what you return. This year, don’t just update a tagline or change your packaging to green. Walk to the back of your factory and ask one question: Where does our water go?If the answer isn’t clear or clean, it’s time to fix it. Need a ZLD system that won’t fail six months after installation? We’ll help you build one that works for your water, your plant, and your future.Visit https://www.shachiengineering.com/ #### Yet Another Award for Team Shachi, Congrats Sukesha Wani Shachi Engineering is proud to share another moment of appreciation for the team. Ms. Sukesha Wani, HR Manager at Shachi, has received the HR Excellence Award from Pimpri Chinchwad University and Pune Business School. The award was presented at the HR Excellence Awards 2026, held at Hotel Orchid, Balewadi, on 6th June 2026. This recognition celebrates her contribution to Learning and Development initiatives at Shachi. People Growth Builds Stronger Organisations At Shachi, learning is treated as an important part of growth. Training, capability building, employee development, and continuous improvement are closely connected with the company’s culture. Sukesha Wani has been actively driving these L&D initiatives. Her work has helped create more structured learning opportunities for employees. It has also supported better skill development across teams. Recognition That Reflects Team Values This award is not only a personal achievement. It also reflects Shachi’s commitment to building a workplace where people are encouraged to learn, grow, and take ownership. Strong HR practices play an important role in creating confident teams. They help people perform better. They also support the organisation’s long-term growth. Congratulations, Sukesha Wani Team Shachi congratulates Sukesha Wani on this well-deserved recognition. Her efforts in strengthening Learning and Development at Shachi continue to make a meaningful difference. This award is a proud moment for her, the HR team, and the entire Shachi family. Yet another appreciation.   Yet another reason to celebrate Team Shachi. #### ZLD for APIs: Evaporate, Separate, Dry and Reuse APIs are the molecules that make medicines work, and their effluents are some of the hardest to treat. Beyond GMP requirements, plants face strict environment norms on TDS/COD/BOD, solvent handling, and safety. Many facilities are expected to run Zero Liquid Discharge (ZLD) or close to it. The goal is simple: prove compliance, keep production moving, and put recovered water back to work. Why API/Pharma effluent is tricky Complex & variable: Every site’s effluent is different and can change with campaigns, raw materials, or process tweaks. Pretreatment matters: Stable ZLD starts with good pretreatment correcting pH, lowering TSS/COD, removing oil & grease, managing hardness, and addressing solvent carryover so downstream units run smoothly. SHACHI’s approach (end-to-end, science-backed) Shachi delivers complete solutions for API/Pharma: pre-treatment, evaporation, crystallisation/centrifuge → final drying → condensate polishing. Designs are grounded in water chemistry, thermodynamics, and the right unit operations, so performance is robust and repeatable. Materials of construction (MOC) Titanium, Super Duplex, SS316L, duplex or specials are chosen for chemical compatibility and long service life. The Shachi way Evaporate what you can, separate what you should, and dry what’s left. 1) Evaporation After pretreatment (pH stabilisation, reducing suspended solids/COD, Hardness Removal, stripping troublesome solvents/foam formers where required), the stream goes to Multiple-Effect Evaporation Falling-film for cleaner liquor and high heat transfer. Forced-circulation for viscous, scaling, or crystal-forming feeds.Add MVR/TVR where viable to cut utilities. Outcome: condensate ready for polishing and a concentrated slurry prepared for salt removal. 2) Crystallise + Centrifuge We control crystal growth (in-effect or external), then centrifuge out mother liquor to get a drier cake/powder that’s easier to handle or dispose per local norms. Recovered liquor loops back as needed. 3) Dryers “Dissolved Solids get separated in ATFD or Spray Dryer”. Agitated Thin Film Dryers (ATFD) or, where appropriate, spray dryers finish the last mile, turning difficult slurry into dry solids/flakes at low residual moisture.  4) Condensate = reusable water Condensate passes through a CPU (carbon/UF/RO as required) so you can reuse water in utilities or process, reducing freshwater draw and OPEX. Why API manufacturers choose Shachi Built around your stream, not a template: The right mix of falling-film/forced-circulation effects, robust crystallisation, and ATFD only where it adds value. Foam/solvent control, anti-fouling velocities, and salt handling are designed in. Faster, predictable start-up: Clear recipes, operator training, practical, reuse numbers, and throughput sooner. Audit-ready from day one: Compatible MOC, hygienic layouts, HAZOP, interlocks, alarms, historian trends, and clean documentation for validation. Utility sense, not just theory: High steam economy, heat integration, and CIP strategies that protect uptime. Controls that keep you confident: PLC-SCADA with recipe logic, safety interlocks and remote support when needed. Optimised & user-friendly: Balanced capex/opex, easy operation, and maintainability tailored to API industry realities. In API ZLD, evaporation concentrates, centrifuges separate and ATFD finishes the tough bits leaving you with dry solids and reusable water. Share your flow data and targets; we’ll right-size the train and prove it on numbers. ### Pages #### About Us About Us Outcomes First. Engineering that De-risks Your Project. “We have all that matters to help you start up faster, run as designed and efficiently, while staying compliant with low lifetime cost.” Years 0 + Projects 0 + Customers 0 + Countries 0 + From a Humble Beginning to a Purpose-Led Engineering Legacy In 1998, Shachi Engineering began in a small outhouse in Pune, started by a technocrat couple with a strong belief that engineering should create value for everyone it touches. What began as a modest initiative slowly grew into a purpose-led organisation. Every project, every customer, and every milestone became an opportunity to give more, to employees, customers, associates, partners, and society. With this belief, Shachi kept growing in people, knowledge, capabilities, infrastructure, and trust.Today, Shachi Engineering is recognised as one of the trusted names in thermal processing technology, delivering reliable and efficient process solutions to industries across India and the world. From complex turnkey systems to advanced process plants, Shachi continues to combine technical excellence with strong customer support. With state-of-the-art manufacturing facilities in Pune and Dahej, spread across 240,000 sq. ft., and clients across 10+ countries, Shachi has grown far beyond its humble beginning. Yet the values remain the same, purpose, courage, growth, and care. 2000 Inception, founded to deliver best in process plants. 2008 Manufacturing facility in Pune. 2010 Expansion with Pilot lab setup 2016 2X Capacity Expansion in existing Pune unit 2017 Technological tie-up for self cleaning evaporator 2020 Second unit at Saykha Gujarat. 2024 Evolved as Trusted Partner for your specialised applications Our Vision To be an organization that is constantly evolving with the courage to enhance the experience of allstakeholders. Values Purpose Growing together through continuous learning, innovation, and shared success. Courage Engineering solutions that create meaningful and lasting impact. Growth Building relationships with responsibility, trust, and commitment. Care Taking bold steps to innovate, evolve, and lead with integrity. Connect With Shachi When You Need To… Build process plants that meet global quality and compliance standards Lower energy usage, optimise utilities, and reduce operational costs Simplify operations through automation and smarter manpower utilisation Achieve smooth audits with complete validation and documentation support Deliver projects on schedule with one trusted engineering partner from concept to commissioning Tell us about your product, capacity, and performance targets, we’ll share a practical process approach, feasibility inputs, and expected ROI outcomes. Get in touch with our Experts for Right Process Solutions #### Agitated Thin Film Dryer (ATFE) Agitated Thin Film Dryer (ATFD) Agitated Thin Film Dryer (ATFD) | Final-Stage Drying for Concentrated Slurries, High TDS Effluent & ZLD Systems When concentrated slurry, viscous residue or high TDS effluent needs to be converted into dry solids, normal drying methods often struggle. An Agitated Thin Film Dryer spreads the feed into a thin, continuously renewed film on a heated surface. The result is controlled final drying, better heat transfer and reliable handling of difficult feeds that are sticky, viscous, scaling or high in solids. Get a quote What Shachi Offers Application-tuned ATFD systems engineered around your feed concentration, viscosity, solids content, drying load and final moisture requirement. Shachi designs Agitated Thin Film Dryers as standalone systems or as part of complete evaporation and ZLD plants. The system can be integrated after MEE, forced circulation evaporator, MVR evaporator or crystallizer depending on the process requirement. Advantages of Agitated Thin Film Dryers Protects sensitive products Converts concentrated slurry into dry solids Useful as a final-stage dryer after evaporation or concentration systems. Handles sticky and viscous feedsContinuous scraping helps process difficult materials that may foul or build up on heated surfaces. Better heat transferThe thin film improves heat transfer and supports faster moisture removal. Suitable for ZLD systemsHelps reduce liquid discharge by converting concentrated effluent into manageable solid residue. Compact and continuous operationDesigned for continuous drying with smaller footprint compared to many conventional drying options. Key Features ATFD rotors with blades or scrapers to create a thin, continuously renewed film. Suitable for concentrated slurry, high TDS effluent, viscous residue and semi-solid feed. Continuous scraping action reduces fouling and improves heat transfer. Designed for final drying after MEE, MVR, forced circulation evaporator or crystallizer. PLC / SCADA-based control with interlocks for temperature, vacuum, rotor load and system safety. Easy access for inspection, cleaning and scraper maintenance. Not happy with wet sludge, sticky residue or incomplete drying? Call Now Agitated Thin Film Dryer Applications ZLD plant final drying MEE concentrate drying High TDS effluent drying Industrial wastewater Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Need help selecting the right configuration? Talk to Our Expert FAQs - Agitated Thin Film Dryer What is an Agitated Thin Film Dryer? An Agitated Thin Film Dryer is an indirect dryer used to convert concentrated liquid, slurry or semi-solid feed into dry powder, flakes or residue. The feed is spread as a thin film on a heated surface, while rotating blades continuously scrape and renew the film. How is ATFD different from ATFE? An ATFE is mainly used for evaporation and concentration. An ATFD is used for final drying. ATFE reduces liquid volume, while ATFD takes concentrated slurry or residue and converts it into dry solids. Where is ATFD used in a ZLD plant? ATFD is generally used near the final stage of a ZLD system. It receives concentrated effluent from MEE, MVR, forced circulation evaporator or crystallizer and converts it into dry solid residue for disposal or further handling. What type of feed can ATFD handle? ATFD can handle concentrated slurry, high TDS effluent, viscous residue, sticky material, salt slurry and certain solvent-based process residues. The exact suitability depends on feed chemistry, solids content, viscosity and temperature sensitivity. Can ATFD work under vacuum? Yes. ATFD can be designed for vacuum operation where lower drying temperature is required. This is useful for heat-sensitive products or solvent removal applications. What maintenance is typical? What is the final output from an ATFD? The final output can be dry powder, flakes, cake or solid residue depending on feed nature, drying duty, scraper design and discharge arrangement. What data is required to design an ATFD? Key data includes feed flow rate, feed composition, solids percentage, viscosity, moisture content, final moisture target, boiling point, solvent details, corrosive nature, operating hours and upstream evaporation system details. Can Shachi integrate ATFD with complete ZLD systems? Yes. Shachi can design ATFD as part of an integrated ZLD system with evaporators, crystallizers, condensers, vacuum systems, automation and downstream solid handling. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Blog Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More Spray Dryer Design: Simple in Appearance, Complex in Reality Spray Dryer Design: Simple in Appearance, Complex in Reality At first glance, a spray dryer machine seems straightforward liquid goes in,Read More Why Do ZLDs Underperform? Uncovering the Truth Behind Water Recovery Challenges Why Do ZLDs Underperform? Uncovering the Truth Behind Water Recovery Challenges Zero Liquid Discharge (ZLD) systems are designed to help industriesRead More ZLD for APIs: Evaporate, Separate, Dry and Reuse ZLD for APIs: Evaporate, Separate, Dry and Reuse APIs are the molecules that make medicines work, and their effluentsRead More Shachi Beading Plant: Built for Global Performance Shachi Beading Plant: Built for Global Performance With installations across India, South East Asia, the Middle East,Read More How CFD Improves Spray Dryer Design for Accuracy and Predictability How CFD Improves Spray Dryer Design for Accuracy and Predictability Spray drying works best when airflow, droplet formation, residence time,Read More Why Particle Size Matters! How Shachi delivers exact particle sizes Why Particle Size Matters! How Shachi delivers exact particle sizes Open any bag of powder, may it be nutraceutical premix,Read More 1 2 3 Next » #### Cage Mill Flash Dryer Cage Mill Flash Dryer Flash Dryer | Flash Dryer Manufacturer | Rapid Drying of Filter Cakes, Pastes & Lumpy Solids Turn hard-to-handle wet solids into uniform, free-flowing powder in seconds. As a Flash Dryer manufacturer, Shachi’s Flash Dryer (Cage Mill Flash Dryer, CMFD) combines high-velocity hot air with a rotor-stator cage mill to disperse and deagglomerate feed on the fly, exposing fresh surface for ultra-fast moisture removal and continuous discharge. Get a quote Cage Mill Flash Dryer: Built Around Your Material Built around your material, CMFD systems follow the cage mill working principle stable screw feeding for wet cakes, cage geometry tuned for controlled dispersion, tangential hot-air entry to create an intense drying vortex, and efficient powder recovery engineered for high throughput, consistent powder quality, and low OPEX. Advantages of Cage Mill Flash Dryer Drying in seconds with extremely short residence time, protecting heat-sensitive products Handles tough feeds (filter cakes, sticky pastes, agglomerates) without lengthy pre-conditioning Consistent, free-flowing outputvia in-chamber dispersion and rapid moisture removal Compact footprint & continuous operationfor easy plant integration Energy-efficient options including hot-air recycle and tuned air/solids loading Key Features Rotor–stator cage mill at the inlet breaks up lumps and disperses feed uniformly into the gas stream (dispersion level tailored to product) Tangential hot-air inlet creates a high-shear drying vortex for rapid evaporation Powder-recovery train with cyclones and/or bag filters; exhaust can be routed for recycle where appropriate Stable feeding via screw or pneumatic feed, matched to cake consistency and throughput PLC/SCADA automation for temperature, airflow, rotor speed, and safety interlocks (inerting/solvent handling where required) Hygienic access & maintenance with quick-open doors and wear-resistant inserts for abrasive solids Need technical clarity or a customised solution in evaporation and drying needs? Call Now Flash Dryer Applications Chemicals (pigments, resins, polymers, catalysts) Minerals (kaolin, bentonite, silica) Food ingredients and nutraceuticals Environmental streams (industrial/municipal sludges) where volume reduction Environmental streams (industrial/municipal sludges) where volume reduction Quick, gentle drying are critical Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Need help selecting the right CMFD configuration? Talk to Our Expert FAQs - Cage Mill Flash Dryer How does a Cage Mill Flash Dryer work? Wet solids are metered (typically by screw feeder) into a rotor, stator cage mill that disperses and deagglomerates the feed. Tangential hot air entrains the particles, drying them in a short vertical or looped path. Dried solids are recovered in cyclones/bag filters; cleaned air is exhausted or recycled. What kinds of materials are suitable? Filter cakes, pastes, and lumpy powders that benefit from instant dispersion, e.g., minerals (kaolin, bentonite), chemicals (pigments, resins), detergents, and select food/nutraceutical ingredients. Environmental sludges can also be dried for volume reduction or energy recovery. Is the cage mill for size reduction or just dispersion? Primarily deagglomeration/dispersion to expose internal moisture; some size reduction of soft agglomerates occurs as needed. Configurations can be tuned to emphasize dispersion without aggressive milling. What residence time and temperatures are typical? Residence time is usually sub-seconds to a few seconds. Gas temperatures can be higher than in other dryers because contact time is short, boosting throughput while minimizing thermal damage. Exact set-points depend on product limits. How is final moisture controlled? By tuning inlet gas temperature/flow, solids loading, rotor speed (dispersion intensity), and recovery back-pressure. Consistent feeding and correct cyclone/bag-filter sizing are key to stable outlet moisture. What about energy consumption and air recycle? CMFDs can be highly energy-efficient due to rapid drying. Where safe and beneficial, hot-air recycle reduces fuel use, design depends on product volatility and hygiene/safety requirements. What information do you need to propose a system? Feed description (cake/paste, particle size, bulk density), inlet/outlet moisture, permissible temperatures, abrasiveness/corrosion concerns, target PSD and bulk properties, throughput, utilities (air/steam/gas/power), and space/height constraints. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Capabilities Capabilities At Shachi Engineering, we innovate, design, manufacture, and commission advanced processing plants that help manufacturers achieve higher efficiency, consistent product quality, and long-term operational reliability.From concept to commissioning, we work as your engineering partner to deliver process systems that perform for decades. Why Industry Leaders Partner with Shachi For over two decades, Shachi Engineering has worked closely with manufacturers to improve plant efficiency, product quality, and process reliability.We believe good engineering starts with understanding the customer’s process. From pilot trials to turnkey execution, we bring practical expertise, clear communication, and dependable support to every project.Our values guide the way we work, with purpose, care, courage, and a strong commitment to delivering solutions that perform in real operating conditions. Two Fully Equipped Manufacturing Facilities Pune, Maharashtra & Bharuch, Gujarat Dual manufacturing locations provide greater production capacity, execution flexibility, and delivery reliability. 40,000 m² Manufacturing Footprint Including 7,600 m² under-crane fabrication area capable of handling large modular assemblies — reducing site work and accelerating installation. Integrated Under One Roof Fabrication, machining, assembly, surface preparation, inspection, FAT, and dispatch are managed internally for tighter quality control and shorter lead times. Expertise in Specialized Materials SS 304 / 316 / 321 / 904L | Duplex Stainless Steel | Hastelloy | Titanium | Higher corrosion-resistant alloys What this means for you: Shorter lead times, faster commissioning, smoother trials, and quicker transition to commercial production. Engineering & Execution Strength 25+ years of process and thermal engineering excellence Modern manufacturing facilities with advanced fabrication capabilities Dedicated project management and process engineering teams Experienced commissioning specialists for reliable plant startup International technology collaborations and strategic tie-ups Specialized expertise in complex thermal process technologies Make a positive impact Connect with Shachi’s team of specialist in process engineering for cleaner, safer and audit ready solutions Contact us Subscribe Newsletters Stay in touch with what’s new at Shachi, know our innovation & stories Subscribe #### Careers Careers Join Shachi We are looking for the right talentAt Shachi, we look for people who are curious, committed, and ready to take on real engineering challenges. If you’re seeking hands-on work, a collaborative team, and space to grow, we’d be glad to hear from you. Key benefits Excellent work culture Global exposure Knowledge & expertise For the right talent, we provide best remuneration and career growth opportunities that surpass individual aspirations. Your name Your email Phone number Department Upload Your Resume #### Case Studies Case Studies Commissioned: 5TPH Beading Plant for Multiple Fatty Acids in Indonesia Commissioned: 5TPH Beading Plant for Multiple Fatty Acids in Indonesia Client: A leading FMCG manufacturer, Indonesia Application: Lauric Acid (C12), Myristic AcidRead More Spray Dryer Ceramic Application Commissioned in Record Time Spray Dryer Ceramic Application Commissioned in Record Time Project Summary Location: Pune, Maharashtra Product: Spray Dryer (Skid-mounted) Evaporation Capacity: 25 kg/hrRead More Spray Dryer Installation for a German Client Spray Dryer Installation for a German Client Product (Client): A leading German MNC based in Bangalore specializingRead More A Global Success – Shachi was chosen to deliver Spray Cooler Plants with 1.5 & 2 TPH capacity by one of the world’s largest food companies. A Global Success – Shachi was chosen to deliver Spray Cooler Plants with 1.5 & 2 TPH capacity by one of the world’s largest food companies. Client’s Product GMS (Glycerol monostearate), Stearic Acid & Palmitic AcidRead More Shachi’s MVR Based ZLD Plant Emerges as a Game-Changer for India’s Top Stainless Steel Manufacturer Shachi’s MVR Based ZLD Plant Emerges as a Game-Changer for India’s Top Stainless Steel Manufacturer Industry : Metals (Steel) Product : ZLD Plant for RO reject applicationRead More Shachi Engineering’s fastrack delivery of 100KLD ZLD Plant with Advanced Self-Cleaning Technology! Shachi Engineering’s fastrack delivery of 100KLD ZLD Plant with Advanced Self-Cleaning Technology! Product – Wastewater unit Timeline – 6 months Plant Capacity – 100KLD Project/Read More Shachi Engineering delivers a CaCl2 plant to the Client in record time Shachi Engineering delivers a CaCl2 plant to the Client in record time Stepping the game for India multi-national GFL is the largestRead More Safe, smart & specialised drying for fragrance manufacturer Safe, smart & specialised drying for fragrance manufacturer An award winning company Zest Aroma is an award winningRead More Shachi Engineering brings the Founder’s vision into reality for Nisarg Crop Care Shachi Engineering brings the Founder’s vision into reality for Nisarg Crop Care Fulfilling the needs of the farmer community Nisarg is aRead More 1 2 Next » #### Chemicals Chemicals Chemical Industry Process Plant Solutions for Drying, Evaporation & ZLD We know what matters for chemical manufacturers — process stability, safety, energy efficiency, and product consistency. Whether you’re scaling capacity, improving energy performance, or managing difficult effluents, we engineer solutions that deliver predictable performance. Our process experts are just a message away. Book a Discussion Chemical Process Engineering Partner for Compliance, Efficiency & Scale-Up Shachi Engineering brings deep process knowledge and practical innovation to support chemical manufacturers. Whether you’re upgrading a batch process, scaling a drying system, optimizing evaporation capacity, or implementing ZLD for challenging streams, Shachi builds solutions aligned with compliance needs and business goals. Chemical Industry Applications We Serve Agrochemicals Specialty Chemicals Dyes & Pigments Intermediates & Fine Chemicals Resins & Polymers Surfactants & Detergent Chemicals Inorganic Chemicals & Salts API & Chemical Precursors Need technical clarity or a customised solution in evaporation and drying needs? Talk to us Why Choose Shachi Engineering for Chemical Process Plants Proven Process Integration Energy-Efficient Solutions Safety & Compliance-Ready Design Customization at Core Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Contact Us Contact Us Shachi Engineering Pvt. Ltd. UNIT I : Gat No. 271, Sr. No. 38, A/Po. Bhare, Tal. Mulshi, Pirangut, Dist.: Pune, Maharashtra – 412115. UNIT II: Plot No. E-185, Saykha Ind. Est., S. No. 44/P, 46/P to 49/P Juned Vagra, Bharuch, Gujarat 392140. Front Desk: +91 20 66546900 Purchase Department: +91 20-66546908 Human Resource:- cvsupport@shachiengg.com Supply Chain: +91 20 6654 6908 / +91 7507591919 materials@shachiengg.com materials@shachiengg.com Sales: +91 20 6654 6904 / +91 7030470233 marketing@shachiengg.com marketing@shachiengg.com #### ETP Plant Effluent Treatment Plant (ETP) ETP Plant | Effluent Treatment Systems for Reliable Compliance Treat industrial wastewater reliably without daily firefighting. Shachi’s Effluent Treatment Plants (ETPs) are built to handle real-world variations in flow and load, so you meet discharge norms consistently and run with predictable OPEX. Get a quote What Shachi Offers End-to-end engineered ETP blocks tailored to your wastewater chemistry, throughput, and site constraints. We design the right sequence, collection & equalization, conditioning, solids/oil removal, organics reduction (as needed), polishing, so outlet quality remains steady and auditable. Benefits We Promise Meet ComplianceStable compliance even with variable influent Chemical ConsumptionLower chemical consumption through controlled dosing and right sizing Odour & Scaling free Reduced odour, scaling, and sludge handling headaches Better uptimeBetter uptime by avoiding shocks and process upsets Clean PerformanceCleaner downstream performance (reuse / membranes / ZLD) Operator FriendlyOperator-friendly systems with clear SOPs and alarms Key Features Stability-first front end: screening and equalization to smooth flow and load swings Conditioning: pH correction and basic chemical conditioning for consistent treatment Solids & oil control: removal of TSS and oil/grease to protect downstream units Organics reduction (where required): stages selected based on COD/BOD behaviour and discharge limits Polishing: filtration/clarification to tighten outlet quality and reduce surprises Controls & monitoring: simple automation options, alarms, and trend logging for audits Materials & layout: practical, maintainable design aligned with effluent chemistry Not Getting Consistent Outlet Quality? Call Now Applications We Serve Specialty chemicals dyes & textiles pharma & intermediates FMCG and food processing engineering & surface treatment mixed-industry Recent Project Name: ZLD Plant | Application: Process Effulents for API | Capacity: 100 KLD MEE Plant with KLAREN-Self-Cleaning technology | Location: Vizag, IndiaName: ZLD Plant | Application: RO Rejects from Steel Plants | Capacity: 20 KLD MVRE based with KLAREN-Self-Cleaning technology | Location: Sahibabad, India Name: ZLD Plant | Application: RO Rejects from Oleo Chemicals | Capacity: 52 KLD | Location: Krishnapatnam, India Name: ZLD Plant | Application: Process Effulents for API | Capacity: 300 KLD MEE | Location: Vizag, India Need Help Scoping Your ETP? Talk to Our Expert FAQs - ETP Plants What is an ETP plant? An ETP (Effluent Treatment Plant) treats industrial wastewater to meet discharge norms by removing solids, oil/grease, and pollutant loads like COD/BOD so discharge is safe and compliant. How is an ETP different from ZLD? ETP focuses on compliant treated discharge. ZLD recovers water for reuse and converts the remaining concentrate into solids so no liquid leaves the site. Why do ETPs struggle in pharma/chemical plants? Because influent characteristics change frequently with campaigns, cleaning cycles, solvents, and raw material variations. The ETP must be designed for variability, not only average values. What data do you need to propose an ETP? Influent report (pH, TSS, COD/BOD, oil/grease, TDS, hardness, metals if any), daily/peak flow, discharge norms, utilities, and footprint constraints. Can the ETP be upgraded later for reuse or ZLD? Yes. A good ETP becomes a strong foundation for reuse and ZLD by delivering stable, lower-load feed to the next stage. How do you ensure consistent compliance and audit readiness? By designing for stability, using simple monitoring and logs, and setting up alarms and diversion logic so off-spec conditions don’t silently pass through. Do you support commissioning and operator training? Yes, start-up support, SOP guidance, and operator training are part of ensuring stable performance after handover. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Evaporators Evaporators Evaporation is a critical step in product concentration and effluent treatment. Shachi’s evaporator systems are designed for high efficiency, low maintenance, and consistent performance, even in the toughest process conditions. Get a quote What Shachi Offers Our evaporators use self-cleaning Klaren technology and MVR options to reduce fouling and improve uptime. With compact footprints and proven reliability, they help industries manage high-solid loads and sensitive process materials. Benefits We Promise Self-cleaning designs with reduced fouling MVR-enabled energy-efficient operation Steady output across varying input conditions Compact size with maximum heat transfer Minimal cleaning downtime and long service life Key Features Klaren self-cleaning technology Energy-saving with mechanical vapor recompression Designed for high fouling or variable TDS feed Easy to integrate with existing systems Reliable, field-tested operation Unsure if your existing evaporator is giving you the best performance? Talk to our team to explore an upgrade or custom-engineered alternative that meets your actual needs. Call Now The Applications We Serve Effluent treatment Specialty chemicals Agrochemicals Food Oils and fats Recent Project Tired of frequent cleaning and inefficient evaporation? Explore a system that works harder, lasts longer, and needs less attention. Talk to Our Expert Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Falling Film Evaporator Falling Film Evaporator Falling Film Evaporator | Gentle, High-Rate Evaporation for Heat-Sensitive Liquids A Falling Film Evaporator is chosen when you need fast concentration with gentle heat exposure especially for heat-sensitive liquids and high-throughput duties. It delivers quick evaporation, better product quality retention, and lower fouling risk, helping plants run steadier with predictable energy use. Refer to the falling film evaporator diagram to understand the compact, high-efficiency flow path that enables these results. Get a quote Falling film Evaporators, Built for Consistent Concentration and Low OPEX Purpose-built systems tailored to your product, solids profile, and hygiene class run standalone or integrated into multi-effect trains for faster payback. Designed to deliver stable operation, reliable concentration targets, and lower running costs, these solutions cover both climbing and falling film evaporator duties to suit different feed behaviors and throughput needs. Advantages of Falling Film Evaporator Gentle on productshort residence time and low ∆T reduce colour change and degradation High throughputexcellent U-values from true thin-film operation Energy efficient seamless pairing with multi-effect, TVR, or MVR schemes Quick start/stop & low hold-upless product in system, faster changeovers Hygienic by design smooth product paths, CIP-ready construction Key Features Precision feed distribution at the top tube sheet with re-distributors for uniform wetting Optimized tube bundle (length, pitch, diameter) to match viscosity and fouling tendency High-efficiency vapour head with demisters/entrainment separators for clean condensable recovery Integrated preheaters/recirculation to maintain wetting at turndown and protect product quality Automation & safety: PLC/SCADA, recipe control, temperature/level/pressure interlocks Materials of construction matched to chemistry: SS316L, duplex/super-duplex, 904L, titanium Not happy with foaming, hot-spots, or uneven distribution? Call Now Falling Film Evaporator Applications Dairy and nutraceuticals Fruit and beverage concentrates Solvent recovery where gentle evaporation Pharma intermediates and extracts Low-to-moderate-viscosity chemicals Solvent recovery where gentle evaporation High quality are critical Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Recent Project Name: ZLD Plant | Application: Process Effulents for API | Capacity: 100 KLD MEE Plant with KLAREN-Self-Cleaning technology | Location: Vizag, IndiaName: ZLD Plant | Application: RO Rejects from Steel Plants | Capacity: 20 KLD MVRE based with KLAREN-Self-Cleaning technology | Location: Sahibabad, India Name: ZLD Plant | Application: Process Effulents for API | Capacity: 300 KLD MEE | Location: Vizag, India Name: ZLD Plant | Application: RO Rejects from Oleo Chemicals | Capacity: 52 KLD | Location: Krishnapatnam, India Need help selecting the right configuration? Talk to Our Expert FAQs - Falling Film Evaporators When should I choose falling film over forced circulation? When the feed is low to moderate viscosity, clean or mildly fouling, and heat-sensitive. Falling film offers high U-values and short residence time; forced circulation is preferred for dirty, scaling, or very viscous streams. How do you ensure uniform wetting of all tubes? Via a precision top distributor (and, on longer bundles, re-distributors) that meter equal flow to each tube. Proper preheat and optional recirculation help maintain film integrity during turndown. Can it handle foaming feeds? Yes, with the right vapour head volume, demisters, controlled ∆T, and, if needed, antifoam dosing or step-wise effect temperatures. Design keeps entrainment low and product in spec. What turndown can I expect? Falling film has a usable turndown but needs minimum wetting flow to avoid dry patches. We design recirculation and distributor geometry so the system stays stable across your operating range. How does a falling film unit integrate with MEE/TVR/MVR? We place it where viscosity is still manageable, ladder effect temperatures for steam economy, and add TVR or MVR to reuse vapour energy, cutting fresh steam while holding quality. What about cleaning and maintenance? Systems are CIP-ready with spray devices and drain/vent points. Smooth surfaces and accessible vapour heads reduce manual cleaning. Correct operation also minimizes wall deposition. What data do you need to size the evaporator? Feed chemistry and viscosity vs temperature, inlet/target solids, allowable product temperature, fouling history, throughput, utilities (steam/power/cooling), required hygiene class, and footprint/height. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Food Food Ingredients Food Processing Plant Solutions for Drying, Evaporation & Process Efficiency We know what matters for the food industry — product quality, hygiene, process stability, and energy efficiency. Whether you’re scaling a line, improving powder properties, or optimizing concentration and utility consumption, we engineer solutions that deliver predictable performance. Our process experts are just a message away. Book a Discussion Food Process Engineering Partner for Quality, Hygiene & Scale-Up Shachi Engineering brings deep process knowledge and practical innovation to support food manufacturers. Whether you’re upgrading a batch process, scaling a spray drying system, improving evaporation efficiency, or reducing operational losses, Shachi builds solutions aligned with food safety expectations and business goals. Food Industry Applications We Serve Dairy & Whey Ingredients Infant Nutrition & Nutraceutical Powders Flavours, Seasonings & Food Premixes Coffee, Tea & Beverage Ingredients Starch & Derivatives Fruit & Vegetable Concentrates Sweeteners & Syrups (concentration lines) Plant-Based Proteins & Ingredients Herbal extract Gum Acacia Gum Arabic Need technical clarity or a customised solution in evaporation and drying needs? Talk to us Why Choose Shachi Engineering for Food Processing Plants Proven Process Integration Energy-Efficient Solutions GMP & Safety Compliance Customization at Core Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Forced Circulation Evaporator Forced Circulation Evaporator Forced Circulation Evaporator | Forced Circulation Evaporator working principle | High-Solids, High-Viscosity, Fouling-Resistant When tough feeds slow down simpler systems, a Forced Circulation Evaporator keeps concentration stable. Based on the Forced Circulation Evaporator working principle, the liquid is pumped at high velocity through an external heater and then flashed in a separator reducing fouling, maintaining heat transfer, and improving reliability on viscous, scaling, or crystal-forming streams. Get a quote Forced Circulation Evaporator Systems Built for Difficult Streams FC systems are sized to match your solids load, viscosity, and fouling tendency, run standalone or integrated into MEE/TVR/MVR or ZLD. The design is tuned to keep circulation stable and heat transfer consistent, so scaling stays under control, product quality is protected, and concentration targets are met reliably. Advantages of Forced Circulation Evaporator Handles difficult feedsviscous, high-solids, crystal-forming, and scaling streams Stable U-values with high tube-side velocities and non-boiling heat transfer in the exchanger Lower downtime via fouling-aware design and easy cleaning access (CIP-ready) Flexible dutyconcentration, mother-liquor conditioning, and FC-crystallizer service Seamless integration into multi-effect and MVR schemes for strong steam economy Key Features External shell-and-tube heat exchanger with high-flow recirculation pump Boiling shifted to flash/separator to limit deposition in the exchanger Optimized hydraulics (recirculation ratio, tube velocity, pressure drop) to mitigate scaling Robust metallurgy options: SS316L, duplex/super-duplex, 904L, titanium, based on chloride/corrosion risks Automation & safety: PLC/SCADA, level/temperature/pressure interlocks, antisurge and low-flow protection Maintenance-friendly: straight-through access, removable bundles, CIP nozzles, isolation valves Not happy with scaling, viscosity limits, or unstable concentration? Call Now Forced Circulation Evaporator Applications ETP/ZLD: RO reject, high-TDS brines, dye/intermediates, pharma/chemical effluents Process: salts and inorganic chemicals, caustic lyes, resin/polymers, sugar/derivatives, gelatin/starches Crystal duty: FC-evaporator with downstream or integrated crystallization for product recovery Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Recent Project Name: ZLD Plant | Application: Process Effulents for API | Capacity: 100 KLD MEE Plant with KLAREN-Self-Cleaning technology | Location: Vizag, IndiaName: ZLD Plant | Application: RO Rejects from Steel Plants | Capacity: 20 KLD MVRE based with KLAREN-Self-Cleaning technology | Location: Sahibabad, India Name: ZLD Plant | Application: Process Effulents for API | Capacity: 300 KLD MEE | Location: Vizag, India Name: ZLD Plant | Application: RO Rejects from Oleo Chemicals | Capacity: 52 KLD | Location: Krishnapatnam, India Need help selecting the right configuration? Talk to Our Expert FAQs - Forced Circulation Evaporators When should I choose a forced circulation evaporator over falling-film? When feeds are viscous, dirty, or prone to scaling/crystallization. FC suppresses tube-side boiling, keeping deposits down and throughput steady where falling-film would foul or stall. How does forced circulation reduce fouling? Liquid is pumped at high velocity through the exchanger; boiling occurs in the flash/separator, not in the tubes. Turbulent flow limits boundary-layer growth and crystal adhesion on heat-transfer surfaces. Can an FC unit be used for crystallization? Yes. With appropriate supersaturation control and residence time, FC duty can be paired with a crystallizer (or configured as an FC-crystallizer) to grow and recover salts while maintaining liquor quality. What information do you need to size an FC stage? Feed chemistry (salts/organics), viscosity vs. temperature, inlet/target solids, allowable temperatures, fouling history, required throughput, utilities (steam/power/cooling), and materials-of-construction preferences How do you integrate FC into a multi-effect or MVR system? We position FC where viscosity and fouling peak (often later effects), set the temperature ladder for steam economy, and match recirculation hydraulics to maintain stability under varying loads. What about cleaning and maintenance? Systems are CIP-ready with strategically placed spray nozzles, drain/vent points, and isolation. Straight-tube or U-tube bundles and removable heads simplify mechanical cleaning when needed. Which materials of construction are typical? SS316L for general service; duplex/super-duplex or 904L for chloride-rich feeds; titanium where corrosion or temperature limits demand it. Selection depends on your detailed feed analysis and lifecycle-cost goals. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Home Turnkey Solutions in Spray Dryers, Evaporators, Beading Plants and Spray Coolers Spray Dryer View More Beading Plant/ Spray Cooler View More Spin Flash Dryer View More Multi-Effect Evaporator View More Agitated Thin Film Dryer View More Integrated Fluidised Bed Spray Dryer View More ZLD Plants View More MVR Evaporator View More Effluent Treatment Plant View More Outcomes First. Engineering that De-risks Your Project. “We have all that matters to help you start up faster, run as designed and efficiently, while staying compliant with low lifetime cost.” Shachi Process Plant Applications Pharmaceuticals Chemicals Food ingredients Oleochemicals Herbal Extracts Agrochemicals Nutraceutical Gum Acacia Process Plants Engineered for Sustainability At Shachi, sustainability is built into every process plant we design. Our solutions improve thermal efficiency, support heat recovery, reduce energy use, enable water reuse, and help clients move toward ZLD-ready operations.We focus on practical, long-term efficiency. This includes the right material selection, modular upgrade options, intelligent process controls, and data-driven optimisation. These choices help improve reliability, reduce resource consumption, and lower lifecycle operating costs.Our commitment to sustainability also goes beyond plant performance. We work to reduce our own operational footprint across manufacturing, utilities, logistics, and infrastructure. For us, sustainability is not a one-time initiative. It is a measurable and ongoing responsibility. View More Globally Trusted Partner India Indonesia Malaysia Thailand Sri Lanka Egypt Russia Saudi Arabia Kenya South Africa Netherland Years 0 + Projects 0 + Customers 0 + Countries 0 + Brochure Download From Spray Dryers and Spray Coolers to complete ETP and ZLD setups, glance through our brochures to know our expertise. Download News Yet Another Award for Team Shachi, Congrats Sukesha Wani Yet Another Award for Team Shachi, Congrats Sukesha Wani Shachi Engineering is proud to share another moment of appreciationRead More Shachi Celebrates World Environment Day with Team Participation Shachi Celebrates World Environment Day with Team Participation Shachi Engineering celebrated World Environment Day with activities that broughtRead More Shachi at PIPOC Malaysia 2025: Beading plants in focus Shachi at PIPOC Malaysia 2025: Beading plants in focus Kuala Lumpur, 18–20 November 2025 — PIPOC 2025 at KLCCRead More #### Integrated Fluidised Bed Spray Dryer Integrated Fluidised Bed Spray Dryer Integrated Fluidised Bed Spray Dryer Manufacturer | Multi-Stage Spray Dryer | Spray Dryer with Fluid Bed Convert liquid feed into free-flowing powder with better control over final moisture, particle size and powder behaviour. Shachi’s Integrated Fluidised Bed Spray Dryer combines spray drying and fluid bed drying in one continuous system. The spray dryer removes the first stage moisture, while the integrated fluidised bed completes final drying, cooling and powder conditioning. Get a quote Trusted by manufacturers worldwide Chosen for critical drying applications by manufacturers who need consistent powder quality, controlled moisture, reliable plant performance and practical process engineering. Shachi designs Integrated Fluidised Bed Spray Dryers for food ingredients, dairy, chemicals, nutraceuticals, pharmaceuticals and specialty powder applications. Advantages of Integrated Fluidised Bed Spray Dryer Better Powder QualityProduces free-flowing powder with improved handling, reduced dusting and better product consistency. Controlled Final MoistureFinal drying happens inside the fluidised bed, giving better control over residual moisture. Agglomerated PowdersSupports larger, porous particles for better dispersibility, instant properties and lower dust generation. Multi-Stage DryingCombines spray drying, fluid bed drying and cooling in one continuous process. Key Features Integrated spray drying and fluidised bed drying in one system.Reduced dusting through controlled particle formation. Improved powder flowability and handling. Optimised air distribution for uniform fluidisation. PLC / SCADA-based control with process instrumentation. Suitable for heat-sensitive products where gentle final drying is required. Custom design based on feed behaviour, drying load, bulk density and powder property requirement. Need technical clarity or a customised solution in evaporation and drying needs? Call Now Integrated Fluidised Bed Spray Dryer Applications Dairy Powders Instant Food Powders Nutraceutical Powders Protein Powders Plant Extracts Flavours & Ingredients Chemical Powders Pharmaceutical Powders Herbal Extracts Agrochemical Powders Detergent & Specialty Powders Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Need help choosing the right spray drying solution? Talk to Our Expert FAQs - Integrated Fluidised Bed Spray Dryer What is an Integrated Fluidised Bed Spray Dryer? An Integrated Fluidised Bed Spray Dryer is a spray drying system where a fluidised bed is built into the lower section of the drying chamber. The spray dryer removes most of the moisture, while the fluidised bed completes final drying, cooling and powder conditioning. How is it different from a conventional spray dryer? A conventional spray dryer generally completes drying inside the main chamber. An Integrated Fluidised Bed Spray Dryer uses multi-stage drying. This gives better control over final moisture, powder temperature, flowability and particle properties. When should I choose an Integrated Fluidised Bed Spray Dryer? It is useful when the final powder needs better flowability, lower dusting, improved solubility, controlled agglomeration or gentle final drying. It is commonly used for food, dairy, nutraceutical, chemical and specialty powder applications. Can this system produce agglomerated powder? Yes. With the right process design and fines return arrangement, the system can support agglomeration. This helps produce larger and more porous particles with better dispersibility and instant properties. Is it suitable for heat-sensitive products? Yes, depending on the product and process requirement. The fluidised bed allows final drying at controlled conditions, which can help reduce unnecessary heat exposure inside the main drying chamber. What information is required to design the system? Basic information includes feed composition, feed solids, viscosity, capacity, inlet and final moisture, heat sensitivity, required particle size, bulk density, solubility requirement and downstream packing or handling needs. Can Shachi customise the system? Yes. Shachi can customise the spray chamber, atomisation system, air flow design, integrated fluid bed, fines return, powder discharge, automation and downstream handling based on the product and process requirement. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Leadership Partner with some of the best minds in the industry Leadership at Shachi believes in building partnerships that last a lifetime. Over the years, we’ve forged hundreds of such relationships by focusing on alignment before ambition, clarity before speed, and sustainability before short-term gains.With us, you’ll always find transparency, respect, and a shared commitment to the right goals. Meet our leaders, and you’ll feel the difference. We believe in developing a lasting competitive edge for your business through our technology, plants and expertise. Marthu Shanbhag Managing Director Linkedin-in We value alignment and sustainability over short wins. If this you believe the same, we must work together. Suruchi Shanbhag Chief Executive Officer Linkedin-in We believe in delivering only the best in every market that we work around the world. If compromises is your villain, you are our hero. Sunil Deo Director Linkedin-in #### Multi-Effect Evaporator (MEE) Multi-Effect Evaporator (MEE) Multi effect evaporator plant | Multi-Effect Evaporator (MEE) | Energy-Efficient Concentration for Process & ETP Concentrate liquids and effluents with minimum steam with Shachi’s Multi effect evaporator plant. A multi effect evaporator (MEE) works where vapour from one vessel heats the next stage at lower pressure, so you reuse heat, reduce energy consumption, and achieve the required concentration more efficiently. Get a quote Leading Multi effect evaporator manufacturer in India designed for Stable Operations and Low OPEX Forward-feed or backward-feed MEE systems engineered around your feed, fouling tendency, and end use. As one of the trusted multi effect evaporator manufacturers in India, Shachi also pairs the right supporting technologies (as needed) for difficult streams and ZLD lines so concentration stays stable and operating costs stay predictable. Advantages of Multi-Effect Evaporators Lower OPEX via steam economylatent heat is reused across effects High concentration ratios to cut storage/transport and prep feeds for drying/crystallization Flexible by designhandles a wide range of viscosities and solids with precise process control More sustainable operations by enabling heat recovery and water reuse Key Features Multi-effect architecture With optimized pressure/temperature ladder for steam economy Forward- or backward-feed configurations selected for viscosity profile, temperature sensitivity, and energy balance Process-integration ready: upstream/downstream with crystallization, drying, and distillation steps Upgrade path: pair with self-cleaning or forced-circulation bodies for fouling feeds, or add MVR for further energy cuts Multi-effect evaporator diagram and architecture with optimized pressure/temperature ladder for steam economy Not happy with your current evaporation setup? Call Now Multi-Effect Evaporators Applications Desalination Food & beverage (juices, dairy, sauces) Chemicals (solvent separation, product recovery) Wastewater/ETP concentration with water recycle Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Recent Project Name: ZLD Plant | Application: RO Rejects from Oleo Chemicals | Capacity: 52 KLD | Location: Krishnapatnam, India Name: ZLD Plant | Application: Process Effulents for API | Capacity: 100 KLD MEE Plant with KLAREN-Self-Cleaning technology | Location: Vizag, IndiaName: ZLD Plant | Application: RO Rejects from Steel Plants | Capacity: 20 KLD MVRE based with KLAREN-Self-Cleaning technology | Location: Sahibabad, India Name: ZLD Plant | Application: Process Effulents for API | Capacity: 300 KLD MEE | Location: Vizag, India Need help selecting the right MEE configuration? Talk to Our Expert FAQs - Multi-Effect Evaporators How does an MEE save energy compared to a single-effect unit? By cascading effects at lower pressures, the vapor from one effect becomes the heating medium for the next, reusing latent heat and reducing fresh steam demand. Forward-feed vs backward-feed, how do I choose? Forward-feed sends fresh feed to the first effect; it’s simple and suits lower-viscosity feeds. Backward-feed introduces feed at the last (hottest) effect, helping viscous or high-solids streams and improving overall temperature driving force. What concentration ratios are possible? MEEs are designed for high concentration ratios; the exact number depends on feed composition, fouling tendency, and temperature limits. (We’ll size effects and heat surfaces from your feed data.) Which industries benefit the most? Desalination, food & beverage, chemical processing, and wastewater treatment, where energy-efficient concentration, product quality, and water recycle matter. How do you handle fouling or scaling feeds? We pair the MEE with suitable bodies, self-cleaning or forced-circulation designs, and optimize velocities and temperature profiles to mitigate deposition. Can an MEE integrate with other unit operations? Yes, common pairings include crystallization, drying, and distillation, enabling complete process trains or ZLD blocks. What do you need to propose a system? Feed chemistry and rheology, inlet/target solids, allowable temperatures, fouling behavior, required product quality, utilities (steam/power/cooling), and footprint/height. We’ll then recommend the number of effects, flow scheme, and body type. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### MVR Evaporator MVR Evaporator Mechanical Vapor Recompression Evaporator Manufacturer in India Concentrate liquids and effluents with much lower steam consumption. Shachi’s MVR Evaporator systems reuse the vapour generated during evaporation as the heating source for the process. This helps reduce dependency on fresh steam, lowers operating cost and makes evaporation more energy-efficient for continuous industrial operations. Designed for chemical, pharmaceutical, food, textile and wastewater applications, Shachi MVR systems are engineered around your feed, concentration target, fouling behaviour, utility availability and plant layout. Get a quote Trusted for Critical Evaporation Applications MVR evaporation is not only about saving steam.It is about designing a stable system that works every day with the right compressor, heat transfer area, circulation pattern, instrumentation and process control.Shachi brings process engineering, thermal design, automation and commissioning experience together to deliver MVR systems that are practical to operate and easier to integrate into new or existing plants. Advantages of MVR Evaporator Lower Steam ConsumptionMVR reuses secondary vapour as heating media, reducing the need for continuous external steam during operation. Lower Operating CostBy reducing fresh steam and cooling water requirements, the system helps bring down daily evaporation cost. Low-Temperature EvaporationSuitable for heat-sensitive products and effluents where controlled evaporation temperature is important. Compact & Energy-Efficient DesignA well-designed MVR system can reduce utility load and plant footprint compared to conventional evaporation systems. Key Features Mechanical vapour recompression system designed as per vapour flow and compression requirement Forced circulation, falling film or self-cleaning evaporator configuration based on feed behaviour Energy-efficient compressor, blower or fan selection Heat recovery through condensate preheating Suitable for high-volume continuous evaporation duties PLC / SCADA-based automation and process monitoring Need technical clarity for your evaporation system? Call Now MVR Evaporator Applications Industrial Effluent Concentration Chemical Processing Pharmaceutical Effluent Food & Ingredient Processing Herbal Extracts Textile & Dye Effluent ZLD Systems Recent Project Name: ZLD Plant | Application: Process Effulents for API | Capacity: 100 KLD MEE Plant with KLAREN-Self-Cleaning technology | Location: Vizag, IndiaName: ZLD Plant | Application: RO Rejects from Steel Plants | Capacity: 20 KLD MVRE based with KLAREN-Self-Cleaning technology | Location: Sahibabad, India Name: ZLD Plant | Application: RO Rejects from Oleo Chemicals | Capacity: 52 KLD | Location: Krishnapatnam, India Name: ZLD Plant | Application: Process Effulents for API | Capacity: 300 KLD MEE | Location: Vizag, India Not happy with your current spray-drying setup? Talk to Our Expert FAQs – MVR Evaporator What is an MVR Evaporator? An MVR Evaporator is an evaporation system that compresses the vapour generated during evaporation and reuses it as heating media. This reduces fresh steam consumption and improves energy efficiency. How is MVR different from a conventional evaporator? A conventional evaporator depends heavily on external steam. An MVR system recycles its own vapour after compression, which reduces the need for continuous fresh steam during operation. Is MVR suitable for all types of liquids? No. MVR suitability depends on feed composition, boiling point elevation, fouling nature, viscosity, scaling tendency, evaporation load and utility cost. A technical evaluation is required before selection. Where is MVR most useful? MVR is useful where evaporation load is high and steam cost is a major operating expense. It is commonly considered for chemical, pharmaceutical, food, textile and ZLD applications. Does MVR eliminate steam requirement completely? MVR generally requires steam or another heat source during start-up. Once the system stabilizes, the requirement for fresh steam can reduce significantly depending on the process design. What type of compressor is used in MVR? The compressor, blower or fan is selected based on vapour flow, pressure rise, temperature lift and process requirement. Correct compressor selection is critical for stable and efficient operation. Can MVR be used in a ZLD plant? Yes. MVR can be integrated into ZLD systems to reduce steam consumption during evaporation. It can be combined with crystallizers, centrifuges, ATFDs or dryers based on the final treatment requirement. What information is required to design an MVR system? Basic details include feed flow rate, feed composition, inlet concentration, final concentration target, operating hours, available utilities, fouling tendency, temperature sensitivity and downstream process requirement. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### News & Events News & Events Yet Another Award for Team Shachi, Congrats Sukesha Wani Yet Another Award for Team Shachi, Congrats Sukesha Wani Shachi Engineering is proud to share another moment of appreciationRead More Shachi Celebrates World Environment Day with Team Participation Shachi Celebrates World Environment Day with Team Participation Shachi Engineering celebrated World Environment Day with activities that broughtRead More Shachi at PIPOC Malaysia 2025: Beading plants in focus Shachi at PIPOC Malaysia 2025: Beading plants in focus Kuala Lumpur, 18–20 November 2025 — PIPOC 2025 at KLCCRead More Shachi at KHIMIYA Russia 2025: Moscow, you were great Shachi at KHIMIYA Russia 2025: Moscow, you were great Moscow, 10–13 November 2025 — Team Shachi had a strongRead More Shachi at IFAT India 2025: Speciality waste water treatment solutions Shachi at IFAT India 2025: Speciality waste water treatment solutions Mumbai, 14–16 October 2025 — At IFAT India 2025 (HallRead More Solving Today’s Water Challenges: Shachi Engineering at IFAT 2024 Solving Today’s Water Challenges: Shachi Engineering at IFAT 2024 This October, Shachi Engineering will showcase its expertise at IFATRead More Shachi Celebrating Engineer’s Day Shachi Celebrating Engineer’s Day Engineer’s Day is a celebration of those who dream inRead More Shachi Foundation Day 2024 Shachi Foundation Day 2024 Shachi Foundation Day 2024 Shachi Engineering’s 26th Foundation Day wasRead More Celebrating Phenomenal Growth and Success! Celebrating Phenomenal Growth and Success! Over the past half-year, Shachi Engineering has achieved remarkable successRead More 1 2 3 Next » Feb 2020 Inauguration of New Facility at GIDC-Saykha, Bharuch, Gujarat. Towards a bigger and brighter future! Shachi Engineering now stands at a moment that is both proud and humbling. Recently, Shachi established a new facility in Bharuch, thereby doubling its manufacturing capacity. While this was indeed an achievement, it also served as a juncture to reflect on where we came from and remind us of the responsibilities that we carry.In its two-decades-long journey, Shachi Engineering has continuously strived to deliver top-quality performance and excellence in design that enables its clients to scale up internationally. It is their growth that has in turn empowered Shachi Engineering to take this big step today. JAN 2019 Sports Day Celebration Our teams got together for inter-departmental matches in various sports categories 4-11 MAR Safety Week Celebration Oath TakingCompetitions for Safety Posters,Presentation on Safety Precaution by workmen and engineers. 8 MAR Women’s Day Celebrating the power of women!At Shachi Engineering, we have several women in leadership roles. 5 JUNE World Environment day Tree Plantation Drive in our campusEmployee awareness program Award’s & Appreciation What drives you at work? Our employees have one more reason!Five our employees were awarded with brand new Cars for their high-performance. JUN 2019 Achievement Celebration 21 JUN 2019 International Yoga Day Dasara Celebration There was a Puja in Workshop, Office & Vehicles New Inning’s… Unit II @ SAYKHA The state-of-the-art manufacturing facility in Gujarat will help us to serve the customers in the region and also serve larger capacity projects. Diwali Celebration Our teams celebrated Diwali in a unique fashion. Travelling back to their childhood favorite, employees from every department made small replicas of forts – a tradition followed in Maharashtra. Medical Check Up The annual health check-up camp for all employees 14 JULY Foundation Day Celebration Shachi Engineering completed 21 years.It has been a wonderful journey. Our teams got together to celebrate the occassion ….and everyone turned into their 21 year old (young!) version. Training Program’s We are committed to conitunal learning and regularly invest in training programs for our employees. Here is a glimpse of some of trainings this year – scheduled as per the annual training calendar. Participation in Exhibition Chemtec 2018 in Mumbai Ankaleshwar Industrial Associations Expo in 2019! Chemspec Hyderabad 2020! Annual Picnic-Diveagar To build a strong team is not an overnight job. It takes time and a variety of situations (even outside of work) for a group of individuals to connect and develop a unique bond to work together cohesively. And to unwind with sports is the best way to learn and develop the bond!Every year, #ShachiEngineering organises a retreat for the Production and Technicians staff. This year, the teams visited Guhaghar on the 4th & 5th of December. No points for guessing the teams played hard and returned all refreshed with a stronger bond. Milestones….! Awards & Recognition..! Shachi Engineering’s teams winning awards, accolades and recognition in various initiatives. #### Oleochemicals Oleochemicals From variability in feedstock to evolving global sustainability norms, processing oleochemicals is more complex than ever before. As demand surges for bio-based alternatives across personal care, food, pharma, and industrial sectors, manufacturers are under pressure to deliver purity, consistency, and efficiency—all while managing energy, emissions, and uptime. Our process experts are just a message away. Book a Discussion A Process Partner for Evolving Oleochemical Demands Shachi Engineering brings deep process knowledge and practical innovation to support the oleochemical industry. Whether you’re upgrading a batch process, scaling a distillation system, or aiming for energy optimization, Shachi builds solutions aligned with both regulatory demands and business goals. Applications Stearic Acid (C18) Palmitic Acid (C16) Myristic Acid (C14) Lauric Acid (C12) Hard Palm Stearin Hydrogenated Palm Stearin (HPS) Glycerol monostearate (GMS) 12 Hydrogenated Stearic Acid (12HSA) Hydrogenated Castor Oil (HCO) Waxes Easters Sorbitan Tristearate (STS) Sorbitan Monostearate (SMS) Waxes Easters Sorbitan Tristearate (e492) Need technical clarity or a customised solution in evaporation and drying needs? Talk to us Why Choose Shachi Proven Process Integration Energy-Efficient Solutions GMP & Safety Compliance Customization at Core Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Partners Partners Be a Partner with Award Winning Process Equipment Solution Provider of India. Grab the excellent opportunity to be a partner with India’s leading and fast growing Process Equipment and Technology solution provider. Shachi Engineering provides complete range of process equipment such as Industrial Dryers, Spray Congealers, Evaporators, Complete Process Plants. Right from Concept-to-Commissioning and beyond Shachi Engineering’s expert team is highly regarded by its customers for the solutions it offers.We offer various cooperation models to our Dealers and Strategic Partners right from distribution and channel sales tie-ups to comprehensive programs covering all the aspects of a strategic partnerships. Distributors We highly value dealer partnership model and they immense value to solution providers like us. We acknowledge distributors provide long term association and market reach to us by making our products and services supply chain more efficient and reliable.Our Solutioning and Engineering capabilities combined with detailed local market knowledge and expertise of distributor helps to drive sales to the next level. Strategic Partners We are looking for strategic partnership collaboration for our specialised range of products and turn key projects.We have various collaboration models that can worked on for strategic partners which can facilitate the tie-up to establish you as one of the business leaders for Shachi Engineering. About Shachi Engineering Over last 2 decades, Shachi has earned market leadership in wide range of Dryers and Evaporators. With a large installed base in multiple industries including Ceramics, Dyes, Food processing and Pharmaceuticals, Shachi has been especially known for its quality engineering with high-performance design. Read More Interested? #### Pharmaceuticals Pharmaceuticals Pharmaceutical Process Engineering Solutions We know what matters for pharmaceuticals process control, product quality, and compliance-ready operations. Whether you’re scaling up, handling heat-sensitive products, or improving throughput, we engineer solutions that deliver predictable performance.Our process experts are just a message away. Our process experts are just a message away. Book a Discussion Pharmaceutical Process Partner for Scale-Up, Compliance & Efficiency Shachi Engineering brings deep process knowledge and practical innovation to support pharma manufacturers. Whether you’re upgrading an existing line, scaling a spray drying system, optimizing evaporation, or strengthening effluent handling, Shachi builds solutions aligned with regulatory expectations and business goals. Pharmaceutical Manufacturing Applications We Serve Microcrystalline Cellulose Powder (MCCP) 101 MCCP 102 MCCP 112 Mannitol Lactose Nutraceutical Pharma & Intermediates Need technical clarity or a customised solution in evaporation and drying needs? Talk to us Why Choose Shachi Engineering for Pharmaceutical Process Plants Proven Process Integration Energy-Efficient Solutions GMP & Safety Compliance Customization at Core Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Self-Cleaning Evaporator Self-Cleaning Evaporator Self-Cleaning Evaporator | Fouling-Free Evaporation for Tough Effluents Keep capacity steady and downtime near zero. Shachi’s self-cleaning evaporators use a fluidized bed of cleaning particles inside vertical shell-and-tube bodies to continuously scrub tube walls, stopping fouling before it starts and sustaining heat transfer over long campaigns. Get a quote What Shachi Offers End-to-end engineered systems that integrate self-cleaning effects into MEE/TVR/MVR trains for high-solids, scaling, or sticky streams. You get a compact design (no over-dimensioning), higher uptime, and lower cleaning/maintenance costs, delivered with Shachi’s local execution and lifecycle support. How the Self-Cleaning Works The fouling liquid flows upward through specially designed tube inlets/outlets. A controlled circulation of solid cleaning media (fluidized by the liquid) provides gentle scouring that removes deposits as they form and disrupts the thermal boundary layer, preserving high heat-transfer coefficients. Benefits We Promise Constant capacity with far fewer shutdowns for cleaning Lower OPEX on chemicals, jet-cleaning, manpower, and lost production Compact plant layout because you don’t oversize to “hide” fouling Better energy performancesustained U-values reduce steam/power per kg evaporated Sustainable operations with longer runs and fewer waste-clean cycles Key Features Self-cleaning tube bundle with fluidized cleaning media and engineered headers Compatible with MEE/TVR/MVR apply self-cleaning to select effects or the whole train Stable heat transfer even on severe scalants (CaSO₄, organics, dyes, etc.) Automation & safety: PLC/SCADA control for flow/level/temp and particle circulation; standard interlocks Proven in the field with local references and service support Not happy with scaling, high steam bills, or frequent cleaning? We’ll audit effect loading, fouling indices, and cleaning cycles, then propose a hybrid train (self-cleaning + conventional bodies or MVR) tailored to your feed and utilities. Call Now Applications We Serve ETP/ZLD lines in textiles, dyes/intermediates, specialty chemicals, pharma waste, handles variable feeds and scalants Process concentration where fouling has limited conventional forced-circulation or falling-film designs Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Recent Project Name: ZLD Plant | Application: Process Effulents for API | Capacity: 100 KLD MEE Plant with KLAREN-Self-Cleaning technology | Location: Vizag, IndiaName: ZLD Plant | Application: RO Rejects from Steel Plants | Capacity: 20 KLD MVRE based with KLAREN-Self-Cleaning technology | Location: Sahibabad, India Name: ZLD Plant | Application: RO Rejects from Oleo Chemicals | Capacity: 52 KLD | Location: Krishnapatnam, India Name: ZLD Plant | Application: Process Effulents for API | Capacity: 300 KLD MEE | Location: Vizag, India Need help choosing the right configuration? Share your feed analysis and targets; we’ll map the effect arrangement, body types, and energy scheme. Talk to Our Expert FAQs - Self-Cleaning Evaporators What makes a self-cleaning evaporator different from a standard one? A self-cleaning design circulates solid cleaning particles through the tube bundle so deposits are removed continuously, keeping tubes clean and U-values high. Standard units rely on periodic chemical/jet cleaning after fouling has already cut capacity. Will the particles erode my tubes or contaminate product? The particles are sized and material-matched to provide mild scouring (not abrasive milling). They remain in a controlled circuit within the effect and are kept out of the product/condensate streams by design. Where in an MEE should I use self-cleaning, one effect or all? Many plants equip the most fouling-prone effect(s) with self-cleaning and keep others conventional; others adopt self-cleaning throughout. The choice depends on fouling propensity, solids profile, and energy integration (TVR/MVR). Can it pair with MVR to cut energy further? Yes. MVR + self-cleaning sustains high transfer coefficients at low primary energy, improving stability and operating cost on difficult effluents. What about very high-solids or scaling feeds (e.g., dyes/textile)? This is a core use case: continuous scouring controls scale growth so you can hold capacity and extend run lengths between maintenance stops. How does it impact CAPEX and footprint? Because you don’t oversize to compensate for fouling, systems are more compact; lifecycle cost drops due to less cleaning infrastructure and downtime. What data do you need to propose a system? Complete feed analysis (salts/organics), viscosity vs. temperature, fouling history, inlet/target solids, temperature limits, desired energy scheme (MEE/TVR/MVR), utilities, and available space. With this, we size the effects, tube bundle, and particle circuit. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Spin Flash Dryer Spin Flash Dryer Spin Flash Dryer Manufacturer | High-Speed Drying of Powders, Crystals & Granules Dry difficult materials like cake, paste and convert them rapidly in free flowing powder with tight control. Shachi’s spin flash dryers use spin agitator rotor to disperse feed into a hot-air vortex, removing moisture in seconds and delivering uniform, free-flowing product, continuously. Get a quote Spin Flash Dryer for High-Shear Dispersion & Instant Surface Drying Application-tuned spin flash systems that address real-world constraints: stable feeding (screw or pneumatic), intense mechanical dispersion, tangential hot-air entry, and efficient powder recovery, engineered for throughput, quality, and low OPEX. Advantages of Spin Flash Dryer Fast, efficient drying via high-speed agitation and hot-air contact Gentle on productwith short residence time to minimize degradation Versatile across materialspowders, crystals, and granules Compact footprintfor space-constrained plants Energy-efficient operationwith potential air recycle Continuous processingfor consistent, large-scale output Key Features Spin agitator rotor to break up and disperse feed uniformly Tangential hot-air inlet creates a drying vortex for rapid evaporation Cyclone separation & collection for clean powder recovery; exhaust can be routed for recycle Stable feeding options (screw or pneumatic) for wet materials Need technical clarity or a customised solution in evaporation and drying needs? Call Now Spin Flash Dryer Applications Chemicals (polymers, resins, pigments, dyes) Pharmaceuticals (e.g., vitamins, extracts) Food (starch, sugar, milk powder, instant coffee) Minerals (bentonite, kaolin, silica) Environmental streams (sludge volume reduction) Environmental streams (sludge volume reduction) Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Need help selecting the right spin flash dryer? Talk to Our Expert FAQs - Spin Flash Dryers How does a spin flash dryer work? Wet solids enter the chamber (typically via screw or pneumatic feed). A high-speed rotor disperses the material into fine particles while tangential hot air creates a vortex that rapidly evaporates moisture. Dried solids are recovered in a cyclone; exhaust air can be routed for recycle. What kinds of materials are suitable? Powders, crystals, and granules across chemical, pharma, food, mineral, and environmental applications—provided the product can be safely dispersed and dried. Why choose spin flash over conventional dryers? It combines very short residence time (gentle on heat-sensitive products) with high throughput, a compact footprint, and potential energy savings via air recycle. How is product quality controlled? By tuning feed rate, rotor speed, inlet air temperature/flow, and residence time to hit target moisture while avoiding overdrying and degradation. What does the powder-recovery train look like? A cyclone separator removes dried solids for collection or further handling; the cleaned air stream is exhausted or routed back depending on the design. Is it energy-efficient? Yes, drying is rapid, and designs can recycle hot air, reducing energy use compared to once-through operation. What information do you need to size a system? Feed form and moisture, desired final moisture/PSD, temperature limits, throughput, and available utilities/space, so we can specify the right rotor, air system, and recovery configuration. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Spray Congealing Beading Plants Spray Cooler Manufacturer | Spray Congealing | Prilling Tower Turn molten oleochemicals into precise, free-flowing beads. Shachi’s beading plant and spray cooling systems convert oleochemicals, castor-oil derivatives, and fatty acids into precise particle size granules. Shachi has been known as one of the most trusted Spray cooler manufacturer in India as well as South east Asia. Get a quote Trusted by manufacturers worldwide Chosen for high-capacity plants by leading food & oleochemical companies, including recent 150 TPD – 240 TPD Beading plant and spray cooling plant installations. Advantages of Beading Plant Bead SizeUniform and custom bead size of 750 um (+/- 150) Multi-Stage Coolingfrom single stage to three stage cooling with integrated fluid bed cooler Designed for harsh climates (to −25 °C)Engineered for ambient swings from −25 °C to high-heat, high-humidity Multiple productsProcess-driven operation enables quick changeovers, as well as controlled recycling Key Features Accurate particle size range: typically 300–1000 μm with tight distribution. Open/closed-loop operation based on product needs. High-efficiency cyclone for fines separation. Integrated & external fluidized-bed post-cooling to avoid lumps during production and shipping. Specially designed air distributor for even inlet air across the chamber. PLC/SCADA-based control with comprehensive instrumentation for reliable, precise operation. Need technical clarity or a customised solution in evaporation and drying needs? Call Now Beading Plant Applications Stearic Acid (C18) Palmitic Acid (C16) Myristic Acid (C14) Lauric Acid (C12) Hard Palm Stearin Hydrogenated Palm Stearin (HPS) Glycerol Monostearate (GMS) 12-Hydrogenated Stearic Acid (12HSA) Hydrogenated Castor Oil (HCO) Waxes Esters Sorbitan Tristearate (STS) Sorbitan Monostearate (SMS) Hydrogenated Palm Stearin (HPS) Glycerol Monostearate (GMS) 12-Hydrogenated Stearic Acid (12HSA) Recent Project Name : Beading Plant | Application: Stearic | Palmitic | Capacity: 5 TPH | Location: Mundra, India Name : Beading Plant | Application: Stearic | Palmitic | Lauric | Myristic | Capacity: 5 TPH | Location: Indonesia Name : Beading Plant | Application: Glycerol monostearate (GMS) | Capacity: 1.5 TPH | Location: Russia Name : Beading Plant | Application: Glycerol monostearate (GMS) | Capacity: 1 TPH | Location: Malaysia Name : Beading Plant | Application: Stearic | Palmitic | Capacity: 3 TPH x 2 | Location: IndonesiaName : Beading Plant | Application: Stearic | Palmitic | Capacity: 5 TPH | Location: Gandhi Dham Need help choosing the right beading solution? Talk to Our Expert FAQs - Spray Congealing Plant (Beading Plant) What is Beading plant and how is it different from spray drying? Beading plants atomizes a melt into a cooled air stream to form solid, spherical beads, no solvent, no evaporation. Spray drying removes solvent from a solution/suspension. Spray congealing offers tighter PSD, shorter height, and easier integration. Which products are suitable for beading? Oleo chemicals, castor-oil derivatives, fatty acids (C12–C18), waxes, GMS/12-HSA/HCO, esters, and similar melts that remain stable on cooling. If the product can be safely melted and solidified without degradation, it’s usually a good candidate. What bead size range can you achieve and how is it controlled? Typical target ranges are in the 750 microns (with a range of +/- 150 μm). Particle size distribution (PSD) is tuned via nozzle selection, melt temperature/viscosity control, chamber airflow design, and post-cooling/air classification for fines management. How do you keep OPEX low? Energy-efficient fans and drives, balanced airflow, heat recovery on exhaust, insulated ducts/chambers, and closed-loop cooling where needed. Automation (PLC/SCADA) maintains setpoints to avoid over-cooling or rework, reducing energy use, rejects, and downtime. What configuration options are available? Open- or closed-loop air systems, single- or multi-nozzle lances, tailored chamber geometry, fluidized-bed post-cooling to prevent agglomeration, cyclone/filters for fines, and hygienic/GMP builds for food & pharma. Systems are modular to match capacity and future upgrades. How easy is cleaning and changeover? Design features include smooth internal surfaces, quick-access doors, warm purge options, and CIP-ready modules for hygienic applications. Changeovers are planned around product melt points and stickiness; with the right design, most line cleans are measured in hours, not days. What utilities, footprint, and capacity should we plan for? Utilities typically include electrical power, chilled water/glycol (or dedicated cooling package), process/clean air, and instrument air. Footprint scales with throughput and cooling duty, from pilot skids (tens of kg/h) to multi-TPH plants. PLC/SCADA integrates with your DCS/MES for recipe control, traceability, and alarms. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Spray Dryer Spray Dryer Spray Dryer Manufacturer | Industrial Spray Drying Plants Shachi Spray Dryers are built to convert liquids, slurries and solutions into stable, free-flowing powders. As a trusted Spray Dryer Manufacturer in India, Shachi designs each system around feed behaviour, heat sensitivity, moisture target, particle size, and final powder properties. With robust engineering and precise controls, Shachi helps manufacturers achieve consistent quality, better recovery and reliable performance across demanding applications. Get a quote Advanced Spray Dryers for Reliable, High-Efficiency Production Shachi Spray Dryers are engineered to deliver consistent output in real plant conditions. Every system is designed around the product, feed behaviour, atomizer selection, airflow pattern, moisture target and process control needs. Built for continuous operation, higher recovery, and stable powder quality, Shachi is trusted as the No. 1 Partner for Spray Dryers and Beading Plants. Advantages of Spray Dryer Wide capacity rangefrom pilot to commercial scale configured to your growth plan Precise Control Handles heat-resistant and heat-sensitive products with precise residence-time control Automation & ControlContinuous, automated operation (PLC/SCADA) for repeatability and lower operator load Flexible layoutsOpen or closed cycle; co-/counter-current; single, two-stage, or multistage Precise Particle sizeEngineered to mitigate practical issues and deliver exact particle size Key Features Atomization options: pressure nozzles or rotary atomizers, single to multi-nozzle systems Optimized chamber design to curb deposition and stabilize droplet paths Open/Closed cycle configurations to suit water or solvent feeds and safety needs Two-stage with integrated (or external) fluid bed for tighter moisture and better instantization Powder handling & recovery: cyclones / scrubbers and downstream collection per product needs Automation & instrumentation: PLC/SCADA with recipe control, alarms, and traceability Need technical clarity or a customised solution in evaporation and drying needs? Call Now Spray Dryer Applications Pharmaceuticals Nutraceuticals Food & Beverages Flavours & Fragrances Herbal Extracts Herbal Extracts Speciality Chemicals Recent Project Name: Spray Drying | Application: MCCP Application | Capacity: 1 TPH | Location: Cuddalore, IndiaName: Spray Drying | Application: High Alumina Ceramic | Capacity: 102 kg/Hr Water Evaporation | Location: Bengaluru, IndiaName: Spray Drying | Application: Water Evaporation | Capacity: 1480 kg/Hr Water Evaporation | Location: Nagpur, IndiaName: Spray Drying | Application: Multiple Applications, 45+ Spray Dryers Supplied | Capacity: | Location: Surat, IndiaName: Spray Drying | Application: Flavors & Fragrance | Capacity: 150 kg/Hr Water Evaporation | Location: Silvasa, IndiaName: Spray Drying | Application: Calcium Chloride (CaCl2) | Capacity: 3750 Kg/Hr. Water Evaporation Not happy with your current spray-drying setup? Let’s Connect,  our team can help specify the right configuration for your products. Talk to Our Expert FAQs - Spray Dryers What feed forms can a spray dryer handle? Solutions, slurries, pastes, gels, suspensions and even melts, provided they can be pumped and dried safely without unacceptable degradation. Nozzle vs. rotary atomizer, how do I choose? It depends on PSD target, viscosity/solids, throughput, and maintenance philosophy. Nozzles use pressure to form droplets; rotary atomizers use a spinning disk. Each offers distinct control ranges and service profiles. What’s the difference between open- and closed-cycle systems? Open cycle uses ambient air (typical for aqueous feeds). Closed cycle recirculates the drying medium and removes moisture via condensation or recovery, preferred for flammable/toxic solvents or stringent safety/hygiene requirements. Can spray dryers manage heat-sensitive products? Yes, by balancing inlet/outlet temperatures, gas flow, and residence time (often seconds), and using two-stage drying with a fluid bed to finish moisture gently. How do you reduce chamber deposition and cleaning downtime? Optimized chamber/air-distributor design, correct atomization, and tuned process set-points minimize wall build-up, cutting unplanned stoppages and burn risks. What issues commonly hurt output, and how are they addressed? Nozzle clogging, uneven drying from poor airflow, sticking, and fouling. Fixes include feed filtration/conditioning, better air distribution, appropriate atomizer/nozzle sizing, and optimized temperatures. What information do you need to size the right dryer? Feed composition and rheology, solids %, target PSD and residual moisture, throughput, solvent type, hygiene/safety class, available utilities, and space constraints. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More #### Sustainability Building a Sustainable Future Engineering Outcomes That Reduce Footprint Sustainability at Shachi is practical. We build process plants that use less energy, recover more heat, and reuse more water, resulting in performance improvements while the footprint reduces. From spray drying to evaporation to ZLD, our focus stays the same: design for efficiency, run for stability, and keep compliance simple. Treat, recover, reuse, without any surprises. For water-intensive industries, sustainability starts with reuse. Our approach supports water recovery through right-sized ETP/ZLD systems, evaporation processesdesigned for stability, and polishing where needed,so freshwater draw reduces and compliance stays consistent. Beyond equipment—action at our sites. Through the Shachi Environment vertical, we strive to encourage conscious manufacturing practices, and work on footprint reduction across facilities and logistics. It’s a continuous effort, measured, improved, and sustained over time. Want to reduce energy, improve recovery, or make your plant ZLD-ready? Share your process, utility limits, and sustainability targets—our team will map a practical path. Book a Discussion News Yet Another Award for Team Shachi, Congrats Sukesha Wani Yet Another Award for Team Shachi, Congrats Sukesha Wani Shachi Engineering is proud to share another moment of appreciationRead More Shachi Celebrates World Environment Day with Team Participation Shachi Celebrates World Environment Day with Team Participation Shachi Engineering celebrated World Environment Day with activities that broughtRead More Shachi at PIPOC Malaysia 2025: Beading plants in focus Shachi at PIPOC Malaysia 2025: Beading plants in focus Kuala Lumpur, 18–20 November 2025 — PIPOC 2025 at KLCCRead More #### Technology Collaborations Technology Collaborations Global Technology Collaborations Bringing the world’s best technologies to our clients Shachi collaborates with leading global technology providers to strengthen its engineering capabilities, offering proven solutions backed by international expertise, executed with Indian manufacturing and service excellence. Self-Cleaning Evaporators An innovative system that continuously removes scale and debris to prevent fouling, reduce maintenance downtime, and maintain maximum energy efficiency. Oil-free Atomizers Oil-free Atomizersfrom 1 kW to 355 kW. customized for customers’ needs, providing pure powder production, no contamination risk, and simplified operating procedures. Calcium chloride (CaCl2) Granulator Reliable fluidized bed granulator hot air furnaces for calcium chloride production (CACL2). MVR- Roots Steam Compressor An integrated enterprise Solutions forRoots BlowersRoots Vacuum PumpsMVR Steam CompressorsMVR EvaporatorsZero Liquid Discharge TechnologySeawater DesalinationWater Treatment Engineering #### Videos Videos Shachi Engineering in Action! Watch the latest videos that will give you a quick walk-through on distinctive product features, capabilities and advantages for each of our Products.The Shachi Engineering Corporate video is a great way to know about our journey and philosophy. Keep us posted with your suggestions and feedback. Success Story Yashashvi Rasayan Pvt. Ltd., Dahej Ankit Pulp and Boards Pvt. Ltd., Nagpur Global Success - Shachi Delivers Spray Cooler Plants Colortex Pvt. Ltd., Surat Nisarga Crop Care Pvt. Ltd., Sangli ZLD and Evaporation Technology for Palm Oil Shachi at the global stage - PIPOC 2023, Malaysia A Day In Life At Shachi Engineering! The Best of Shachi Engineering - 2023 Shachi at the global stage - PIPOC 2023, Malaysia Highlights of Dahej Industrial Expo 2023 Shachi Engineering now in Gujarat! A Global Milestone - Dispatch of Advance Spray Cooler Plant in Southeast Asia Year in Review 2018 Launching Self-Cleaning Evaporator #### Webinar Webinar Get Exclusive Insights and the Latest Industry Updates Explore our Webinars, connect with industry experts and like-minded professionals. Innovations in Spray Drying Technology and the Latest Trends in Spray Dryer Design . Speaker :Shrikant Datir, Vijay Singh Building a High-End Spray Drying Facility for Premium Products: Essential Design & Process Considerations Speaker : Dhruv Patel, Shrikant Datir Optimizing processes with Spray Drying Tailored Applications in Food, Pharma and Chemical products Speaker : Shrikant Datir Introduction to Spin Flash Dryer Principles and Applications Speaker :Shrikant Datir A Technology Webinar ZLD with MVR-Based Evaporation Plant Speaker : Sagar Wagh, Shrikant Datir Watch Video #### Zero Liquid Discharge Plant Zero Liquid Discharge Plants ZLD Plant Manufacturer | Zero Liquid Discharge Systems for Compliance & Water Reuse Turn wastewater into a resource. As a trusted ZLD manufacturer, Shachi delivers robust ZLD technology that combines proven pretreatment, membranes, evaporation, and crystallization to recover clean water and convert the remainder into solid salts meeting discharge norms while cutting your freshwater draw. Get a quote ZLD Technology for Faster Payback and Reliable Compliance End-to-end zero liquid discharge plants built around your stream, site, and recovery goals. Our ZLD technology follows a proven ZLD process treat, recover, and convert the remainder into manageable solids, so you reduce freshwater draw, stay compliant, and keep operations steady. The result is predictable running cost and a faster, measurable payback. Advantages of Zero Liquid Discharge Plant High water recoveryto reduce fresh-water dependence and tanker costs Guaranteed compliancewith auditable quality logs and alarmed interlocks Optimized OPEXvia steam economy, MVR integration, and heat recovery Scale & foul control by pairing the right body type, dosing, and velocities Compact, modular layoutsthat fit brownfield sites and future expansion Lifecycle supportpilot studies, commissioning, training, remote monitoring Key Features Smart pretreatment: equalization, pH/ORP control, DAF/clarification, filters, organics/solvent stripping where needed Membrane block: UF for SDI control, RO/NF for high rejection, MBR for biological loads when applicable Evaporation suite: falling-film for clean streams; forced-circulation/self-cleaning for viscous or scaling feeds; MVR for lowest steam use Solids finishing: ATFD or crystallizer with centrifuge/filter press; salt washing and drying options Heat & condensate recovery: preheaters, closed-loop cooling, condensate polishing for reuse Automation & safety: PLC/SCADA, recipe control, historian, CIP, interlocks for level/pressure/temperature, solvent-safe design where applicable Materials of construction: SS316L to duplex/904L/Ti/Hastelloy based on chloride, solvent, or corrosion risk Need help selecting the right configuration? Call Now Zero Liquid Discharge Plant Applications Textiles & dyes Specialty chemicals Pharma & intermediates Food & beverage Electronics Metals & surface treatment Mixed-industry CETPs aiming for near-zero discharge and high water reuse Recent Project Name: ZLD Plant | Application: Process Effulents for API | Capacity: 100 KLD MEE Plant with KLAREN-Self-Cleaning technology | Location: Vizag, IndiaName: ZLD Plant | Application: RO Rejects from Steel Plants | Capacity: 20 KLD MVRE based with KLAREN-Self-Cleaning technology | Location: Sahibabad, India Name: ZLD Plant | Application: RO Rejects from Oleo Chemicals | Capacity: 52 KLD | Location: Krishnapatnam, India Name: ZLD Plant | Application: Process Effulents for API | Capacity: 300 KLD MEE | Location: Vizag, India Need help scoping your ZLD? Talk to Our Expert FAQs - ZLD Plants What is a ZLD plant and how is it different from a conventional ETP? A ZLD plant recovers water and turns the rest into solid salts, zero liquid leaves your site. Conventional ETPs discharge treated water to sewer/surface bodies; ZLD eliminates that discharge by adding membranes, evaporation, and crystallization. How much water recovery can I expect? Typical total recovery ranges from 80–95% depending on chemistry (TDS/TSS/organics/solvents). We confirm via treatability and pilot data, then size each block to your target. How do you control OPEX in ZLD? By removing loads early (good pretreatment), using staged membranes to cut evaporator duty, selecting MVR or multi-effect schemes for steam economy, and recovering heat from condensate/exhaust. Correct hydraulics and anti-scalant dosing keep cleaning and downtime low. Which evaporator should I choose, falling film, forced circulation, self-cleaning, or MVR? It depends on viscosity and fouling: falling film for clean/low-viscosity; forced circulation or self-cleaning for scaling/high-solids; MVR where electricity is reliable and you want the lowest steam. Many systems mix these by effect. What happens to the salts and sludge? Crystallized salts are dewatered (centrifuge/filter press) and routed to approved disposal or, where feasible, salt washing/recovery. Sludges from pretreatment are handled via the same dewatering line with separate containers and documentation. How do you ensure consistent compliance and auditability? Online sensors (pH, conductivity, turbidity, TOC where applicable), flow/level logging, and SCADA historian provide traceable records. Interlocks prevent off-spec reuse, and auto-divert tanks isolate excursions. What information do you need to propose a ZLD system? Composite/segregated feed analysis (TDS, hardness, alkalinity, silica, COD/BOD, oils/solvents, metals), daily/seasonal load, recovery and reuse targets, allowable temperatures, utilities (power/steam/cooling), footprint/height, and any site compliance constraints. Blog Importance of Fuel and Power Efficiency in Spray Drying Processes Importance of Fuel and Power Efficiency in Spray Drying Processes Spray drying is an energy-intensive process. Every plant depends heavily onRead More Importance of Downtime Control in Spray Drying Plant Performance Importance of Downtime Control in Spray Drying Plant Performance Downtime is one of the biggest hidden costs in sprayRead More 5 Critical Challenges in Spray Drying for Nutraceuticals 5 Critical Challenges in Spray Drying for Nutraceuticals Nutraceuticals are made for human consumption. They include health supplements,Read More ### Media #### (No Title) URL: https://www.shachiengineering.com/spray-drying-dfe-pharma-01/ #### (No Title) URL: https://www.shachiengineering.com/spray-drying-dfe-pharma-02/ #### (No Title) URL: https://www.shachiengineering.com/spray-drying-bosch/ #### (No Title) URL: https://www.shachiengineering.com/spray-drying-ankit-pulp-board/ #### _ Chemicals URL: https://www.shachiengineering.com/home/_-chemicals/#main #### _Cage Mill Flash Dryer – key features image URL: https://www.shachiengineering.com/forced-circulation-evaporator/_cage-mill-flash-dryer-key-features-image/#main #### 1 URL: https://www.shachiengineering.com/zld-plant-3/attachment/1/#main #### 1.5 TPH Spray Cooling Plant Commissioned for Global Oleochemical Manufacturer URL: https://www.shachiengineering.com/1-5-tph-spray-cooling-plant-commissioned-for-global-oleochemical-manufacturer/1-5-tph-spray-cooling-plant-commissioned-for-global-oleochemical-manufacturer-2/#main #### 10 URL: 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