Transform your heat-sensitive materials from "impossible" to proven.
Pharma actives that degrade at 50°C?
Probiotics that die in standard dryers?
Botanical extracts losing flavor?
Send your material. We'll prove it works in 5 days.
Submit Your Material
Free bench test. 5-7 days. Complete analysis.
Why We're Confident
Our P-50 pulse dryer — the same platform your bench test sample scales up on before we size your production unit.
How Pulse Atomization Actually Works
The atomizer core: no nozzle, no wheel, no wear parts.
No high-pressure pumps. No spinning wheels. No wear parts to replace every few weeks. A 250 mph hot gas stream atomizes and dries your liquid feed in under one second — at feed pump pressures around 1 psi. That's how Pulse Atomization Spray Drying hits inlet temperatures up to 1,000°F without scorching heat-sensitive material: the exposure is too short for the heat to do damage.
| Feature / Metric | Open Tube Atomizer (PASD) | Conventional Pressure Nozzle |
|---|---|---|
| Feed Line Pressure | Low pressure (~1 psi) | High pressure (up to 5,000 psi) |
| High-Pressure Pump | Not required (uses low-pressure peristaltic pump) | Required (up to 5,000 psi; requires frequent overhauls) |
| Solids / Viscosity Limit | Up to 50% solids (up to 80% on heavy minerals) and 5,000 cP | Typically limited to 15–25% solids and ~200–300 cP before clogging |
| Typical Repair / Maintenance Time | ~10 minutes to replace peristaltic tubing | High maintenance; can require pump overhauls every 2 weeks and frequent nozzle changes |
| Handles Abrasives / Corrosives | Excellent (unrestricted straight ceramic pipe and rubber feed line) | Poor (rapid orifice erosion/corrosion leading to out-of-spec powder) |
Actual results vary by material and are confirmed through your free bench test — not marketing claims.
What You Get
Complete Technical Analysis
Thermal profile, particle size distribution, moisture content, and potency retention testing—fully documented.
Fast Turnaround
Submit Monday, get results Friday. Our engineering team is ready to discuss your next steps immediately.
Zero Risk
Completely free. No credit card. No obligations. If it doesn't work, we'll explain why.
What Process Engineers Say After Testing It
"Pulse Drying Systems has been an invaluable asset — and a great example of what a company should be — in helping us solve difficult production problems for critical health ingredients."
Founder, Tesseract
"Working with Pulse helps us deliver innovative solutions to the world's biggest water challenges" — eliminating the need for over 12,500 pounds of plastic packaging in the process.
Scientist, Nalco Water (an Ecolab Company)
"Pulse makes the best powders" — enabling us to give customers a stable, high-quality health and wellness powder instead of a liquid concentrate.
Manager, GTX Technologies
Pulse's low-temperature spray drying made it possible to produce IconicA® Powder — a more bio-available, stabilized form of Vitamin A than retinol — at production scale.
Principal Scientist, CoValence Laboratories
The Process
Bench Test
Send a 3 oz sample with your process specs. We run it on our lab-scale P-5 dryer.
Full Report
5-7 days: complete thermal, particle, and potency analysis + engineering consultation.
Scale-Up Path
Move to our P-50 dryer (10x scale) for multi-day trials, then size your production unit — from P-5 up to P-1500.
Is Pulse Drying Right for Your Material?
We'd rather tell you upfront than waste your team's time. Here's where pulse atomization consistently wins — and where a conventional spray dryer may still be the better tool.
Pulse atomization is a strong fit when:
- Your material degrades, denatures, or loses potency under standard drying heat
- You're currently freeze-drying and need a continuous, lower-cost alternative
- Your feed is viscous or high-solids and keeps clogging conventional nozzles
- You need tight, consistent particle size distribution
- Throughput needs fall under ~1,500 lb of water removed per hour
A conventional dryer may still make sense when:
- You're producing commodity-scale powders (20,000+ lb/hr water removal, e.g. bulk milk powder)
- Your material is stable, low-value, and unaffected by high-shear atomization
- You already have depreciated conventional equipment with capacity to spare
Questions?
How long is the bench test?
▼5-7 business days. Complete thermal analysis, particle characterization, and potency testing—not a preliminary screen.
What if it doesn't work?
▼We'll tell you directly. If pulse combustion doesn't solve your challenge, we'll explain why and discuss alternatives.
Is the test really free?
▼Completely free. No credit card. No obligations. We're confident in our technology.
Can I talk to an engineer?
▼Yes. Call James Rehkopf at (415) 726-3536 or email jrehkopf@pulsedry.com. No gatekeepers.
How is pulse atomization different from freeze-drying (lyophilization)?
▼Freeze-drying runs in 24–48 hour batches and requires expensive vacuum and refrigeration infrastructure. Pulse atomization dries the same heat-sensitive materials continuously in under a second, at roughly 20% of typical freeze-drying operating costs — while matching freeze-dried quality on bioactivity, taste, and morphology for many materials. We confirm the match for your specific material through a pilot demonstration trial, not with a generic claim.
How does this compare to our current spray dryer on cost and maintenance?
▼Conventional spray dryers atomize through high-pressure nozzles or spinning wheels (up to 5,000 psi) that wear out and require frequent pump overhauls. Pulse dryers atomize with a gas-dynamic stream at a feed pump pressure of about 1 psi — with no nozzles to replace, and worn pump tubing swapped in roughly 10 minutes by your own team without any service contract. Higher inlet temperatures (up to 1,000°F) also deliver high thermal efficiency to lower overall energy use. Specific process parameters and material metrics are verified during your pilot demonstration trial.
What throughput can pulse dryers handle, and is there a path from lab to full production?
▼Our line scales from the pilot-scale P-10 (10 lb/hr evaporation) up through the commercial P-1500 (1,500 lb/hr of water removed). Projects begin with a lab bench test, move to a P-10 pilot trial to produce initial powder, and then translate directly to a production unit using the exact same atomizer architecture across a 150-fold range. Note: for commodity-scale output above 1,500–2,000 lb/hr (such as bulk milk powder at 30,000 lb/hr), conventional dryers are still the proper fit.
Do you have experience with materials like mine?
▼We've run favorable results on 200+ different materials, with strong track records in minerals, specialty chemicals, food, and nutraceutical products. That includes specific wins in shear-free microencapsulation, high-solids mineral slurries, and delicate proteins. Tell us your material and challenge, and we'll give you an honest assessment — including for probiotics and botanical extracts, where we evaluate suitability case-by-case.
Talk to Us
No gatekeepers. Reach out directly to the person who can actually help.
James Rehkopf
President — Leadership | Finance | Sales
Phone: (415) 726-3536
Email: jrehkopf@pulsedry.com
Kyle Simonsen
VP Engineering | Site Manager | Controller
Phone: (480) 283-7500
Email: ksimonsen@pulsedry.com