The development of surface stickiness of droplets of sugar and acid-rich foods during spray drying can be explained using the notion of glass transition temperature (T-g). In this work, criteria for a safe drying regime have been developed and their physical basis provided. A dimensionless time (psi) is introduced as an indicator of spray dryability and it is correlated with the recovery of powders in practical spray drying. Droplets with initial diameters of 120 mum were subjected to simulated spray drying conditions and their safe drying regime and 41 values generated. The model predicted the recovery in a pilot scale spray dryer reasonably well. (C) 2004 Elsevier B.V. All rights reserved.