End-to-End Powder Processing
Applications
From fermented biological products to advanced battery materials and thermal coating powders, Arch provides the full processing chain—upstream liquid blending, spray drying, calcining, and downstream dry blending—under one roof.
Application
Fermented Products
Spray drying is the industry standard for converting liquid fermentates into stable, shelf-ready powders. We manage the complete processing chain—from precise upstream blending of fermented broths and excipients, through gentle spray drying that preserves bioactivity, to downstream dry blending for finished formulations.
Our controlled drying conditions protect heat-sensitive live cultures, enzymes, and bioactive metabolites, delivering consistent powder properties batch after batch.
Typical Products
Application
Battery & Energy Materials
Advanced energy storage demands powders with precise morphology, composition, and particle size distribution. Spray drying delivers spherical, homogeneous particles purpose-built for electrode slurry casting—and our calcining services develop the crystal structure required for electrochemical performance.
We handle the complete sequence: upstream precursor slurry blending for compositional homogeneity, spray drying for spherical particle formation, and high-temperature calcining up to 2000°F for phase transformation.
Typical Materials
Application
Plasma Spray & Thermal Coating Powders
Thermal spray coatings demand feedstock powders that are highly spherical, free-flowing, and precisely sized to match plasma gun specifications. Our spray drying process produces powder feedstocks purpose-engineered for plasma, HVOF, and flame spray applications.
Precision slurry blending upstream ensures homogeneous chemistry in every particle. Downstream calcining burns out binders, sinters particles, and develops the target phase composition required for coating performance.
Typical Materials
Our Capability
End-to-End Processing Under One Roof
Most toll processors handle a single step. We manage the complete chain—from raw liquid preparation through finished powder—eliminating handoffs, reducing lead times, and preserving process control.
Upstream Liquid Blending
Precise preparation of liquid feedstocks—solutions, slurries, and emulsions—to exact compositional specifications before drying.
Spray Drying
Convert liquid to free-flowing powder in a single continuous step. Control particle size, morphology, moisture, and bulk density.
Drying & Calcining
High-temperature thermal processing to remove organics, drive phase transformations, and develop the target material microstructure.
Dry Blending
Blend spray-dried product with other ingredients to create finished formulations with uniform composition and optimized flow.
Technical Advantages
Why Spray Drying?
Spray drying outperforms drum drying, freeze drying, and tray drying across most industrial applications—delivering superior powder properties at production scale.
Single-Step Conversion
Transform liquid feedstocks directly into dry powder in seconds. Spray drying eliminates multiple downstream processing steps.
Precise Particle Engineering
Control particle size, shape, bulk density, and morphology. Achieve tightly specified distributions for demanding applications.
Preserves Sensitive Materials
Gentle evaporative cooling during drying protects heat-sensitive bioactives, enzymes, and reactive compounds.
Proven Scalability
Predictable scale-up from grams to tons. Process parameters developed at pilot scale translate reliably to full production.
Continuous High-Throughput
Continuous operation enables high-volume campaigns. Consistent outlet conditions ensure batch-to-batch reproducibility.
Versatile Feedstocks
Handles solutions, slurries, emulsions, and suspensions. Suitable for aqueous and organic systems across a wide viscosity range.
Ready to Discuss Your Application?
Our technical team has deep experience across fermented products, battery materials, thermal spray powders, and beyond. Tell us about your project and we'll propose a processing approach.