In March 2021, All Season Herbs Pvt. Ltd. successfully commissioned its second 100 L/hr all-stainless-steel spray drying plant — the single largest capital investment in the company's history. Positioned within the extraction facility for seamless liquid-to-powder process flow, this plant increased total spray-dried extract output capacity by 200%, setting a new benchmark for consistency, particle-size control, and batch-to-batch reproducibility across our entire range.
The Investment That Changed Our Capacity
The second spray drying plant was not an incremental upgrade — it was a strategic commitment to meeting the growing global demand for pharmaceutical and nutraceutical-grade spray-dried herbal extracts with guaranteed consistency. An all-stainless-steel construction was specified throughout: from the feed pump and drying chamber to the cyclone separator and bag filter — eliminating contamination risk and meeting the most stringent GMP requirements for food and pharmaceutical-grade manufacturing.
Positioning the new plant inside the extraction facility — rather than as a separate downstream unit — was a deliberate engineering decision. It eliminates intermediate handling of liquid extracts, reduces oxidation and contamination exposure during transfer, and allows continuous process control from extraction to dried powder in a single monitored environment. The result is a tighter, more traceable production chain with fewer points of variation.
A 200% increase in spray drying capacity is not just a production milestone. It means we can commit to larger volumes, tighter turnaround times, and — most importantly — an even higher level of batch-to-batch consistency for every client we serve.
All Season Herbs Pvt. Ltd. · March 2021What Spray Drying Means for Product Quality
Spray drying is the gold standard method for converting liquid botanical extracts into stable, free-flowing powders with defined particle size, moisture content, and active marker concentration. Our all-SS plant produces extracts that meet the most demanding downstream formulation requirements — from direct compression tablets to hard-shell capsules and functional food applications.
100 L/hr Evaporation Rate
All-stainless-steel · GMP-compliant constructionControlled Particle Size
D50/D90 verified per batch · Uniform powder morphology
The second 100 L/hr all-stainless-steel spray drying plant commissioned inside the All Season Herbs extraction facility, Whitefield, Bangalore — March 2021.
Part of a Long-Term Manufacturing Vision
The commissioning of the second spray drying plant followed the 2018 inauguration of our GMP-compliant finishing and packing facility — which introduced AHU-controlled blending and milling environments. Together, these investments represent a phased, deliberate build-out of a fully integrated herbal extract manufacturing operation: from raw material intake to finished, packed, labelled product.
For our clients, the practical impact is straightforward: larger volume orders fulfilled faster, with no compromise on the consistency parameters that matter to pharmaceutical and nutraceutical formulators. Every batch from the new plant is accompanied by a full Certificate of Analysis — particle size, moisture, assay, and microbiology — verified against the same specification used for every previous batch.
