Spray Drying Equipment Market Outlook, 2030

Spray drying, a process that converts liquid or slurry materials into dry powders using hot gas, has become essential in sectors such as food and beverages, pharmaceuticals, chemicals, and biotechnology. Its origins date back to the early 20th century, with commercial adoption gaining momentum in the 1950s, initially in the dairy industry for powdered milk production. Companies in this sector employ diverse promotional strategies, including participation in trade shows, digital marketing, direct sales, and collaborations with research institutions and end-users, enabling customized solutions and improved market penetration.

Innovations such as automation and integration of artificial intelligence into spray drying systems have enhanced efficiency and product quality, further strengthening market presence. The changes in consumer lifestyles over the last decade as a result of rapid urbanization have resulted in a high demand for processed and ready-to-eat food products. Consumers' busy lifestyles have been exacerbated by an increase in dual-income levels, living standards, and the demand for convenience have led to the increased consumption of processed food. Dedert successfully commissioned its latest Spray Drying and Evaporation plant for plant-based protein in June 2022.

Dedert provided the specialty protein developed for its solubility functionality by EverGrain (by AB InBev). EverGrain's new protein production facility on AB InBev's St. Louis brewery campus was completed to upcycle grains saved during the brewing process into delicious, nutritious, and environmentally friendly ingredients. These barley-based ingredients can be found in a wide range of foods and beverages.

Regulatory compliance is a critical aspect of the industry, with manufacturers adhering to stringent frameworks such as FDA and USDA standards in the United States, along with certifications like Safe Quality Food (SQF), Good Manufacturing Practice (GMP), and Grade A for dairy ingredients. Internationally, ISO standards and regional regulations ensure consistent product safety and quality, building consumer trust and facilitating global market access.

According to the research report "Global Spray Drying Equipment Market Outlook, 2030,", the Global Spray Drying Equipment market was valued at more than USD 6.72 Billion in 2024, and expected to reach a market size of more than USD 9.65 Billion by 2030 with the CAGR of 6.35% from 2025-2030. The increasing demand for processed and convenience foods is a significant driver, as spray drying ensures product stability, extended shelf life, and consistent quality. In the pharmaceutical sector, spray drying is essential for enhancing drug solubility, bioavailability, and the production of advanced formulations, particularly for poorly water-soluble compounds.

Technological advancements, including rotary atomizers, multi-stage drying systems, and automation with real-time monitoring, have further improved efficiency, reduced operational costs, and enabled the production of highly uniform powders. Spray drying technology plays a pivotal role in the production of infant formula, ensuring the powders are nutritionally complete and adhere to stringent safety standards set by the WHO and FDA. Under the FDA's 21 CFR Part 106 regulations, infant formula production is subject to rigorous quality control measures.

Furthermore, the technology's prowess in encapsulating delicate nutrients, such as DHA and probiotics, without subjecting them to thermal degradation, is propelling a surge in premium equipment sales. This trend is especially pronounced in the Asia-Pacific markets, buoyed by rising birth rates and increasing disposable incomes that bolster formula consumption.

Additionally, environmental and sustainability concerns are prompting manufacturers to develop energy-efficient, low-emission spray drying equipment, aligning with global trends toward greener industrial processes. Furthermore, the rise of personalized medicine, functional foods, and nutraceuticals presents additional avenues for growth, as spray drying enables precise control over particle size, encapsulation of sensitive compounds, and high-quality product output.

Market Drivers

• Rising Demand from the Food and Dairy Industry: The global demand for convenience foods, powdered milk, infant formula, and instant beverages has been increasing significantly. Spray drying equipment is essential for converting liquid foods into stable powdered forms without compromising nutritional value, flavor, or shelf life. This rising consumption of processed and powdered food products directly fuels the need for advanced spray drying systems that offer high efficiency, better yield, and improved product consistency. Manufacturers are increasingly adopting spray dryers to meet the quality standards and scalability requirements of large food processing operations, further boosting market growth.
• Pharmaceutical and Nutraceutical Applications: The pharmaceutical sector relies heavily on spray drying technology for producing inhalable drugs, controlled-release formulations, and powdered active pharmaceutical ingredients (APIs). The ability of spray drying equipment to produce uniform particle sizes, enhance solubility, and ensure precise drug dosage makes it indispensable for pharmaceutical manufacturing. Additionally, the growth of the nutraceutical segment, including powdered supplements and probiotics, has expanded the scope for spray drying systems. This demand for high-quality, stable powders in healthcare applications acts as a strong driver for market expansion.

Market Challenges

• High Initial Capital Investment: One of the main obstacles for small and medium-scale manufacturers is the significant upfront cost of spray drying equipment. Advanced systems with automated controls, energy-efficient features, and precise particle size management can be prohibitively expensive, limiting their adoption in emerging markets. Additionally, the cost of maintenance, spare parts, and skilled labor to operate these complex machines adds to the financial burden, creating a barrier for smaller players seeking to enter the market.
• Energy Consumption and Operational Costs: Spray drying is an energy-intensive process that requires high temperatures and continuous operation, which can lead to high electricity and fuel costs. This energy demand also raises concerns about the environmental footprint of operations. Manufacturers are pressured to optimize drying parameters and invest in energy-efficient technologies, but operational costs remain a challenge, especially in regions with high utility prices. Balancing efficiency, quality, and cost is a persistent hurdle for the industry.

Market Trends

• Automation and Advanced Process Control: Modern spray drying equipment is increasingly being integrated with automation, sensors, and advanced process control systems. This allows real-time monitoring of temperature, airflow, and particle size, improving product quality, reducing wastage, and enhancing overall operational efficiency. The trend toward smart manufacturing aligns with Industry 4.0 initiatives and is expected to become a standard feature across the market.
• Focus on Sustainable and Energy-Efficient Solutions: Environmental concerns and regulatory pressures are pushing manufacturers to adopt energy-efficient spray drying technologies. Innovations such as closed-loop systems, low-temperature drying, and recovery of heat and solvents are gaining traction. Sustainability is no longer optional; companies are leveraging eco-friendly designs to reduce carbon footprint, cut energy costs, and appeal to environmentally conscious consumers, reflecting a significant trend shaping the market’s future.Rotary atomizer spray dryers dominate the global spray drying equipment industry because they offer superior efficiency, uniform particle size distribution, and high adaptability for large-scale continuous production in food, dairy, and pharmaceutical applications.

Rotary atomizer type is the largest segment in the global spray drying equipment industry mainly because of its ability to deliver consistent quality, flexibility across a wide range of materials, and cost-effectiveness for large-volume operations. In rotary atomizer spray dryers, liquid feed is atomized into fine droplets using a high-speed rotating disk, creating uniform particles with controlled size and improved solubility, which is crucial for industries like dairy, food, pharmaceuticals, and chemicals.

This precise control over particle size makes rotary atomizers the preferred choice for producing milk powders, whey proteins, instant coffee, powdered flavors, and infant formula, where consistency and reconstitution properties directly influence consumer acceptance. One of the strongest advantages of rotary atomizer technology is its ability to handle high-capacity production, making it ideal for large-scale plants that dominate the dairy and food sectors. Unlike nozzle atomizers, rotary atomizers do not require frequent cleaning or replacements, which reduces downtime and operational costs, offering greater efficiency for companies producing thousands of tons of powders annually.

This reliability and continuous operation capability explain their popularity among large manufacturers in North America and Europe, where advanced dairy and pharmaceutical industries demand equipment that guarantees both performance and compliance with strict hygiene standards. Rotary atomizers are also favored in pharmaceuticals, where spray drying is essential for enhancing solubility and bioavailability of active ingredients, as uniform particle sizes help in controlled drug release and improve formulation stability.

Single-stage spray drying equipment is the largest type in the global spray drying industry because it offers simplicity, cost-effectiveness, and high efficiency for producing a wide range of powdered products in the food, dairy, and pharmaceutical sectors.

Single-stage spray drying systems dominate the global spray drying equipment industry primarily due to their operational simplicity, affordability, and suitability for high-volume production of stable powders across multiple industries. In a single-stage system, the feed solution is atomized into droplets and dried in one continuous step, making the process faster and easier to manage compared to more complex multi-stage systems. This straightforward design reduces equipment costs, installation requirements, and maintenance expenses, which makes it particularly attractive for large-scale manufacturers seeking efficiency at lower capital investment.

Food and dairy industries, which are the largest users of spray drying technology, prefer single-stage systems for producing milk powder, whey protein, coffee, flavors, and instant mixes, where uniform dryness and long shelf life are critical. The single-step drying method ensures that powders achieve the desired moisture content and stability while minimizing processing time, which is important for meeting growing global demand for processed and functional food products. In pharmaceuticals, single-stage dryers are widely used for drying heat-sensitive drugs, excipients, and active pharmaceutical ingredients because of their ability to preserve product quality while delivering consistent particle size.

Moreover, the adaptability of single-stage dryers across multiple feed materials - liquids, slurries, and emulsions - enhances their appeal for diverse applications in chemicals and nutraceuticals as well. Manufacturers in Asia-Pacific, North America, and Europe also favor single-stage systems due to their reliability, scalability, and proven performance in producing bulk powders for both domestic use and exports.

Open cycle spray drying equipment is the largest type in the global spray drying industry because it is cost-effective, easy to operate, and highly efficient for producing bulk food, dairy, and chemical powders where heat sensitivity is not a major concern.

Open cycle spray drying systems dominate the global market because they represent the most widely used and economical configuration, making them the preferred choice for industries requiring high-volume powder production such as dairy, food and beverages, chemicals, and nutraceuticals. In an open cycle system, the drying gas usually hot air passes once through the chamber, comes into direct contact with the atomized droplets, and is then released to the atmosphere, making the process straightforward and cost-efficient.

This design is particularly effective for non-heat-sensitive materials like milk powders, whey proteins, coffee, powdered flavors, detergents, and various industrial chemicals, which constitute the largest share of spray-dried products globally. Open cycle systems are less expensive to build, install, and maintain compared to closed cycle systems, which require additional equipment for gas recycling and solvent recovery.

As a result, manufacturers in both developed and developing regions favor open cycle spray dryers for their bulk production lines, especially in dairy plants and large food processing facilities where efficiency and cost control are critical. The ability of open cycle systems to handle large feed volumes with consistent drying performance ensures that companies can meet rising consumer demand for convenient and long-shelf-life powdered foods, including infant formula, protein powders, and instant beverages. Another important factor supporting their dominance is ease of operation and maintenance, since the design is relatively simple and does not require specialized training or high operational expertise, making it accessible to a wide range of manufacturers

Co-current flow spray drying equipment is the largest type in the global spray drying industry because it allows gentle drying of heat-sensitive products, ensures better retention of nutritional and functional properties, and is widely used in food, dairy, and pharmaceutical sectors.

Co-current flow spray drying equipment has become the dominant type in the global spray drying industry because of its versatility, product quality advantages, and suitability for a wide range of industries that require high-value powders with preserved nutritional and functional characteristics. In this configuration, both the hot drying air and the atomized feed move in the same direction inside the drying chamber, which means that the wettest particles are exposed to the hottest air at the beginning of the process, and as they dry, they move into progressively cooler air zones.

This gradual temperature reduction significantly reduces the risk of thermal degradation, making co-current dryers the preferred choice for heat-sensitive products such as milk powder, whey proteins, infant formula, coffee, flavorings, enzymes, and pharmaceutical ingredients. The food and dairy industries, which together represent the largest share of spray drying applications globally, benefit greatly from co-current systems since maintaining solubility, taste, aroma, and nutritional value of powders is crucial for consumer acceptance and regulatory compliance.

For example, in the dairy sector, co-current drying ensures that essential proteins and vitamins in milk powder are not damaged, allowing manufacturers to meet the demand for high-quality infant nutrition, sports supplements, and functional food ingredients. Similarly, in the pharmaceutical industry, co-current spray dryers are critical for producing sensitive drugs, probiotics, and bioactive compounds that require precise control of particle size and stability without losing efficacy.

Another reason for their dominance is their operational flexibility, as co-current dryers can handle a wide range of feed materials, viscosities, and compositions, making them highly adaptable across different industries. They are also preferred because they produce free-flowing powders with uniform particle size distribution and good reconstitution properties, which are essential for instant beverages, soups, and nutritional products.

Food and dairy applications are the largest in the global spray drying equipment industry because of the massive demand for milk powders, whey proteins, infant formula, instant beverages, and flavoring agents, which rely heavily on spray drying for stability, shelf life, and quality preservation.

The food and dairy sector holds the largest share in the global spray drying equipment industry due to its vast scale, critical need for product preservation, and increasing consumer demand for convenient, functional, and nutritious products. Spray drying is one of the most essential processes in the food and dairy industries, as it allows the transformation of liquid and semi-liquid materials into stable powders that are easy to store, transport, and use. The dairy industry alone has been a key driver of this dominance, as milk powders, whey proteins, and infant formula are global staples that depend almost entirely on spray drying technology.

Milk powder is indispensable not only in developing regions where refrigeration infrastructure is limited but also in international trade, where spray-dried products account for a major share of dairy exports from countries like the U.S., New Zealand, and members of the European Union. Similarly, whey protein powders and caseinates, widely consumed in sports nutrition, dietary supplements, and functional foods, are produced using spray drying systems because they retain nutritional properties and dissolve quickly when reconstituted.

Infant formula, one of the most sensitive and regulated food products worldwide, requires advanced spray drying to ensure consistent quality, safety, and nutrient preservation, further reinforcing the importance of the dairy segment. Beyond dairy, the food industry also relies heavily on spray drying for products such as instant coffee, tea powders, soups, sauces, seasonings, and flavorings.

The process is vital for encapsulating volatile compounds, preserving taste and aroma, and extending shelf life, which directly aligns with modern consumer preferences for ready-to-use, convenient, and long-lasting products.North America is the largest in the global spray drying equipment industry due to its advanced food processing, pharmaceutical, and dairy sectors supported by strong technological innovation and high demand for functional and convenient food products.

North America’s dominance in the global spray drying equipment industry can be attributed to a combination of highly developed industries, consumer demand for processed and functional products, and the region’s emphasis on technological innovation and quality standards. The United States and Canada in particular host some of the world’s leading food and beverage companies, dairy product manufacturers, and pharmaceutical giants, all of which rely heavily on spray drying processes to produce high-quality powders, flavors, additives, and pharmaceutical ingredients. Spray drying is widely used in North America’s dairy sector for transforming milk into milk powder, whey protein, and infant formula, industries where the U.S.

has been a global leader for decades. The region’s growing demand for functional foods, nutraceuticals, and dietary supplements also fuels the market, as spray drying is an efficient method for encapsulating probiotics, vitamins, and bioactive ingredients to preserve their functionality and extend shelf life. Beyond food, the strong presence of the pharmaceutical industry in North America further accelerates adoption, as spray drying is crucial for improving solubility and bioavailability of active pharmaceutical ingredients, particularly for novel drug formulations.

The region also benefits from high levels of R&D investment and the presence of leading equipment manufacturers, which continuously introduce advanced spray drying technologies such as energy-efficient systems, closed-loop designs, and equipment that minimizes product degradation. Stringent regulations on food safety and pharmaceutical quality in North America create a favorable environment for advanced spray drying equipment, as companies prioritize precise control, hygiene, and compliance, further stimulating market growth.

• In July 2025, Aenova expanded its Killorglin site by adding a spray drying platform designed for producing amorphous solid dispersions (ASD) and inhalation powders.
• In January 2025, Dover Corporation acquired select assets from Carter Day International's petrochemical division, integrating them into its MAAG business unit to enhance specialized dewatering and drying equipment capabilities for the plastics industry. This acquisition strengthens Dover's position in the industrial drying and pelletizing equipment sector.
• In November 2024, SteriPharma unveiled a completely new pharmaceutical powder unit that has next-generation features since it is meant to produce spray drying. The equipment is built to satisfy the high level of quality control and hygienic conditions required in relation to the increasing need for quality pharmaceutical products.
• In May 2024, GEA unveiled its latest addition to its lineup of pharmaceutical spray dryers at ACHEMA in Frankfurt. The newly introduced GEA ASEPTICSD® aseptic spray dryers mirror the functions, sizes, capacities, design, and chamber geometry of the standard GEA PHARMASD pharmaceutical spray dryers. This similarity facilitates a seamless transition from non-sterile to sterile spray drying, streamlining both time and cost efficiencies.
• In April 2023, RELCO, part of Koch Separation Solutions, launched the Parvus pilot spray dryer specifically for food applications. The system was available in two versions: the Parvus Nomad, a single-stage dryer suited for test batches and smaller production runs with up to 10 kg (22 lbs.) of water evaporation, and the Parvus Multi-Stage dryer, which featured a wide-body design and could manage larger volumes of up to 25 kg (55 lbs.) of water evaporation.