United States Spray Drying Equipment Market Overview,2030

The evolution of the spray drying equipment market in the United States has been closely tied to the industrialization of food processing, pharmaceuticals, and chemicals over the past century. Spray drying technology was introduced in the US in the early 20th century, initially applied to milk powder production to support the expanding dairy industry. By the 1950s, it became widely adopted in coffee and powdered food manufacturing, aligning with the post-war surge in packaged and convenience foods. In the pharmaceutical sector, US companies integrated spray drying techniques in the late 20th century to enhance bioavailability of poorly soluble drugs and to handle heat-sensitive compounds. This period also marked the beginning of encapsulation technologies, widely used in both food and pharma. Over the decades, advancements in atomizer design, flow control, and drying chambers led to higher efficiency and product uniformity, enabling broader adoption. The 21st century brought integration of energy-efficient systems, automation, and digital monitoring, aligning with the US emphasis on sustainability and operational efficiency. The rise of nutraceuticals, probiotics, and functional food in the 2000s further expanded demand for precision spray drying systems. Today, the US is one of the most mature markets, with strong research and development investments, advanced manufacturing facilities, and strict compliance with FDA and USDA regulations, ensuring quality and safety. This historical trajectory positions the US market as both technologically advanced and highly regulated, with innovation and regulatory compliance driving its global leadership in spray drying applications.

According to the research report ""US Spray Dying Equipment Market Overview, 2030,"" published by Bonafide Research, the US Spray Dying Equipment market is anticipated to grow at 5.75% CAGR from 2025 to 2030. The US spray drying equipment market is shaped by a balance of growth drivers, restraints, opportunities, and challenges. On the demand side, increasing consumption of processed foods, functional dairy products, and powdered beverages such as coffee and protein powders significantly drives market growth. The pharmaceutical industry also fuels adoption, with spray drying enabling solubility enhancement and controlled release formulations, crucial for advanced drug delivery systems. Nutraceuticals and dietary supplements, a booming sector in the US, further stimulate demand for encapsulation through spray drying. On the supply side, technological advancements in atomizer efficiency, energy optimization, and digital monitoring systems enhance productivity, aligning with industry demand for precision and cost-effectiveness. However, restraints include high equipment costs, intensive energy requirements, and complex maintenance, which can limit adoption among small and medium enterprises. Additionally, alternative drying technologies, such as freeze drying, pose competitive pressure in applications requiring superior preservation of bioactivity. Opportunities lie in the growing focus on sustainable manufacturing, with US companies investing in closed-loop systems and heat recovery technologies to reduce emissions and energy consumption. The increasing emphasis on clean-label and fortified products, particularly in infant nutrition and plant-based foods, also provides growth avenues. Challenges remain in regulatory compliance, with stringent FDA and USDA requirements necessitating high standards in hygiene, material selection, and validation processes. Furthermore, labor shortages in advanced manufacturing sectors could slow equipment adoption in some facilities. Overall, the market dynamics reflect strong growth potential, underpinned by innovation and stringent quality demands, but tempered by cost and regulatory complexities.

In the United States spray drying equipment market, product segmentation is defined by the dominance of rotary atomizer, nozzle atomizer, fluidized, and centrifugal systems, each serving distinct industrial needs. Rotary atomizer spray dryers hold a significant share, particularly in large-scale dairy and food processing plants, due to their ability to produce uniform particles and handle high-capacity production. US dairy manufacturers, especially in Wisconsin and California, use rotary atomizers extensively for milk powders, whey proteins, and infant formula. Nozzle atomizer spray dryers are increasingly preferred in the pharmaceutical and nutraceutical industries, where precision in droplet size and gentle processing of heat-sensitive materials is crucial. Their adoption is growing in biotech hubs such as Massachusetts and New Jersey, where encapsulation of probiotics, vitamins, and drug intermediates is common. Fluidized spray dryers, though a smaller segment, are gaining traction in specialty chemical applications and materials science research in the US, as they offer excellent control over moisture and particle uniformity. They are also being explored in advanced applications like ceramic powders and catalysts, with adoption concentrated in industrial states such as Texas and Ohio. Centrifugal spray dryers maintain niche applications, particularly in producing fine powders for cosmetics and laboratory-scale pharmaceutical testing, with installations often found in R&D facilities across the country. Across all categories, US manufacturers emphasize automation, energy efficiency, and compliance with FDA and USDA standards. The product landscape reflects a mature market, where equipment choice is driven by industry-specific needs for quality, precision, and large-scale capacity.

In the United States, spray drying equipment adoption by stage single-stage, two-stage, and multi-stage varies across industries, depending on product quality requirements, scale, and cost considerations. Single-stage spray dryers are widely used in the food and beverage sector for bulk products like coffee, milk powder, and flavorings, where simplicity and cost-efficiency are key. Their dominance remains strong in large dairy hubs, particularly in the Midwest, where production volumes are high, and the need for consistent powders outweighs the requirement for highly specialized particle characteristics. Two-stage spray dryers are gaining ground in the US pharmaceutical and nutraceutical industries, where controlled moisture levels, better encapsulation, and improved powder solubility are critical. Facilities in biotech and pharma-heavy regions such as New Jersey, California, and Massachusetts increasingly rely on two-stage systems to meet strict FDA quality standards while optimizing drying efficiency. Multi-stage spray dryers, though representing a smaller share, are strategically important in high-value applications such as infant formula, probiotics, specialty chemicals, and plant-based nutrition. Their ability to integrate fluidized beds and advanced cooling mechanisms makes them suitable for sensitive materials where particle size, flowability, and stability are crucial. Multi-stage adoption is particularly rising in advanced food research facilities and pharmaceutical manufacturing hubs. Across all categories, the US market emphasizes equipment that meets GMP, USDA, and FDA regulations, with growing demand for multi-stage systems as manufacturers seek to differentiate products with higher solubility, stability, and shelf life. This segmentation demonstrates a clear trend toward advanced, multi-functional systems tailored to evolving consumer and regulatory demands.

The US spray drying equipment market by cycle open and closed illustrates differences in application, safety, and energy considerations across industries. Open-cycle spray dryers dominate in food and dairy processing, where water is the primary solvent, and safety risks are minimal. They are heavily utilized in large-scale dairy facilities across states such as Wisconsin, California, and New York for producing milk powders, whey proteins, and coffee powders. Their cost-effectiveness and efficiency make them the default choice in high-volume production environments. Closed-cycle spray dryers, though representing a smaller share, are critical in industries dealing with solvents, toxic materials, or oxygen-sensitive products. In the US pharmaceutical sector, especially in areas like Massachusetts and New Jersey, closed-cycle systems are deployed to handle solvents such as ethanol and acetone, ensuring both operator safety and environmental compliance. Similarly, in the chemical sector, closed-cycle spray dryers are used for catalysts, pigments, and polymers where solvent recovery and explosion prevention are necessary. Adoption of closed systems has also increased due to stricter environmental regulations by the Environmental Protection Agency (EPA) and Occupational Safety and Health Administration (OSHA), pushing manufacturers toward safer and cleaner production processes. Although open-cycle dryers remain dominant due to their lower cost and suitability for food applications, closed-cycle systems are gaining traction with the US focus on sustainability, solvent recovery, and minimizing emissions. This shift is most visible in pharma, biotech, and specialty chemical industries, where product safety, quality, and regulatory compliance outweigh initial equipment costs.

The US spray drying equipment market by flow configuration—co-current, counter-current, and mixed flow reflects diverse processing requirements across industries. Co-current flow spray dryers are the most widely used in the US, especially in the food and dairy sector, where they allow rapid drying of heat-sensitive materials by having the hot air and feed flow in the same direction. Major dairy processing hubs use co-current flow dryers to produce milk powders, coffee creamers, and flavors while maintaining nutritional integrity. Counter-current flow dryers, though less common, are utilized in industries requiring longer drying times and lower final moisture content. In the US chemical sector, particularly in states like Texas and Louisiana, counter-current dryers are employed for producing detergents, catalysts, and specialty chemicals where durability and low residual moisture are critical. Mixed-flow systems are increasingly relevant in pharmaceuticals and nutraceuticals, as they combine the benefits of both co-current and counter-current configurations, delivering powders with optimized solubility, stability, and particle uniformity. Their adoption is rising in pharmaceutical hubs such as New Jersey and California, where advanced formulations demand precise drying conditions. Across all flow configurations, US manufacturers prioritize energy efficiency, automation, and compliance with environmental and safety regulations. Co-current systems dominate due to their efficiency and suitability for bulk food processing, but the growing need for specialty applications and high-value products is driving demand for counter-current and mixed-flow designs. This segmentation reflects a mature market where equipment configuration is chosen based on balancing cost-efficiency, product quality, and regulatory compliance.

Applications of spray drying equipment in the United States span food & dairy, pharmaceuticals & nutraceuticals, chemicals, and other niche sectors, each contributing significantly to market growth. Food & dairy represents the largest share, with spray drying widely used in milk powder, whey protein, coffee, tea, and flavor production. The Midwest and California lead in dairy spray drying facilities, supplying both domestic and export markets, with strong demand for infant nutrition and protein powders. Pharmaceuticals & nutraceuticals are rapidly expanding applications, with US companies employing spray drying to enhance drug solubility, stabilize heat-sensitive compounds, and encapsulate probiotics, vitamins, and bioactives. Leading pharma hubs such as Massachusetts, New Jersey, and California are at the forefront of adoption, supported by strict FDA regulatory frameworks. Chemical applications also play a vital role, particularly in the production of detergents, pigments, polymers, and catalysts, with significant usage concentrated in Texas and Louisiana. The ability of spray drying to produce uniform, free-flowing powders makes it indispensable in industrial chemical processes. Other applications include ceramics, cosmetics, and advanced materials, where fine particle production is essential for performance and innovation. Universities and research institutes across the US also utilize pilot-scale spray dryers for R&D in materials science, nanotechnology, and biotechnology. Across applications, regulatory compliance, sustainability, and process optimization remain central themes. Food and dairy continue to dominate volumes, but pharmaceuticals, nutraceuticals, and specialty applications are driving higher-value growth, underscoring the US market’s balance of scale and innovation.


Considered in this report
• Historic Year: 2019
• Base year: 2024
• Estimated year: 2025
• Forecast year: 2030

Aspects covered in this report
• Spray Drying Equipment Market with its value and forecast along with its segments
• Various drivers and challenges
• On-going trends and developments
• Top profiled companies
• Strategic recommendation

By Product
• Rotary Atomizer
• Nozzle Atomizer
• Fluidized
• Centrifugal

By Stage
• Single-Stage
• Two-Stage
• Multi-Stage

By Cycle
• Open
• Closed

By Flow
• Co-Current
• Counter-Current
• Mixed Flow

By Application
• Food & Dairy
• Pharmaceuticals & Nutraceuticals
• Chemical
• Others Show more