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Spray Dryer Inspection & Crack Testing Services
Find cracks before they become contamination risks. Our electronic scanning detects visible and non-visible defects across 100% of your spray dryer, with no dyes or chemicals, and our welders repair them in the same shutdown.
- ISO 9001 & SafeContractor
- No dyes or chemicals
- 100% surface coverage
- Inspect + repair in 24–48 hrs*
*Extra time may be needed if extensive repairs are required.
100%
24–48 hrs
24/7
Why Regular Spray Dryer Crack Inspection Matters
Every spray dryer will eventually develop cracks in its stainless-steel weld joints or sheet metal. Thermal cycling, mechanical stress, CIP and corrosion all take their toll. Regular crack testing finds these defects early, while they are small and simple to repair.
What Our Spray Dryer Inspection Covers
We inspect the complete drying system, not just the chamber, so nothing is left unchecked before you restart production.
Components inspected
- Drying chamber weld joints
- Drying chamber sheet metal
- Fluid bed upper compartment
- Fluid bed lower compartment
Defects we detect
- Cracks, visible and non-visible
- Incomplete welds
- Corrosion cavities
- Porosity
Fluid beds are critical to the complete drying system, so we inspect and repair both compartments alongside the dryer. We also inspect cyclones and bag filters and silos and process tanks.
Chemical-Free Electronic Crack Detection
Our electromagnetic crack scanning technology inspects 100% of the dryer surface and finds defects that cannot be seen by eye. Because no dyes or chemicals are used, nothing is introduced into your food production zone.
Electronic scanning vs dye penetrant testing
BioScan electronic scanning
- No dyes or chemicals in the dryer
- Detects non-visible defects
- 100% surface coverage
- No chemical clean-up afterwards
Dye penetrant testing
- Dyes, cleaners and developers
- Surface-breaking defects only
- Coverage depends on areas tested
- Clean-up required before production
Our Spray Dryer Inspection Process
A complete inspection, including repairs, is usually finished within 24–48 hours, so you are quickly back in production.
Access without scaffolding
- Portable aluminium gantry, adjustable from 1.5m to 14m
- Supports up to 475kg; tested annually and checked before every use
- Two technicians work from each end, covering 180° each
- IRATA-certified rope access for shafts and hard-to-reach areas
Spray Dryer Crack Repair & Food-Grade Polishing
Finding cracks is only half the job. Our qualified welders repair every defect and polish it to food-grade standards during the same visit, so you don’t need a second shutdown.
- Weld repairs and food-grade polishing on site
- Option to use your own on-site or local welders
- Every repair re-inspected, including the heat-affected zone
- Fluid bed compartment repairs included
Case study: shutdown duration reduced through integrated repairs →
Industries We Serve
We inspect spray dryers for food and beverage manufacturers, where hygiene, audits and uptime matter most.
Food Ingredients & Additives
Beverage
Trusted by leading food and dairy producers
Why Choose BioScan for Spray Dryer Inspection
The quickest, cleanest and safest way to check the integrity of your spray dryer.
Recent Case Studies
Tank Inspection Following Asset Ageing Concerns
Shutdown Duration Reduced Through Integrated Repairs
Hidden Corrosion Behind Product Build-Up
Spray Dryer Inspection FAQs
How often should spray dryers be inspected?
We recommend inspecting your spray dryer at least once a year. In one case, a client waited five years between inspections and many defects were found, leading to higher repair costs and risk.
Why is regular spray dryer inspection important?
Thermal cycles, mechanical stress, CIP and corrosion gradually cause cracks and weld defects. Left undetected, these can lead to unplanned downtime, costly repairs, product quality issues and recalls.
What inspection technology does BioScan use?
We use electronic, non-destructive crack scanning technology that detects visible and non-visible defects, including cracks, incomplete welds, corrosion cavities and porosity, without any dyes or chemicals.
How is electronic testing different from dye penetrant testing?
Our electronic scanning covers 100% of the surface, detects non-visible defects and introduces no dyes or chemicals into your dryer, making it a cleaner inspection method for food production environments.
How long does a spray dryer inspection take?
A complete inspection, including repairs, can usually be carried out within 24–48 hours. Extra time may be needed if extensive repairs are required.
Does BioScan repair cracks during the inspection?
Yes. Our qualified welders carry out repairs and food-grade polishing during the project, and every repaired area is re-inspected. You can also use your own on-site or local welders.
Is scaffolding required?
No. We use our bespoke gantry platform, rope access, ladders or a combination, so no scaffolding is needed.
Which access method will you use?
It depends on the construction of your spray dryer. Our technicians select the right method, or a combination, to inspect the full surface safely and efficiently.
Do you inspect fluid beds, cyclones and bag filters?
Yes. We inspect and repair the upper and lower compartments of fluid beds, and also offer cyclone, bag filter, silo and tank inspections.
Do you provide spray dryer inspections outside the UK?
Yes. We ship our access equipment directly to your plant and fly our technicians to your site.
Can we rent or buy the access gantry?
Yes. You can rent or purchase our gantry as part of an inspection contract, store it locally and move it between your factories. Our technicians then travel directly to your sites.
Talk to a Spray Dryer Inspection Specialist
Share your dryer details and shutdown dates, and our team will come back with a quote.