operation type

product format

Privacy Policy

User Agreement

Terms of Service

Default Confirmation

If too long

This form auto replies from Zendesk on submission
on Trigger ID: tbc
https://vekamafsupport.zendesk.com/agent/admin/triggers

Admin Notification

New submission from {form_title}

Messages backup

Notify Teammedia of submission

Submission from Making.com Ad Campaign

Maker - Product Challenge

Products

Technologies

About us

Changemakers

Drying API Equipment

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

API making equipment must observe rigorous quality control standards across the entire manufacturing process. The pharmacodynamic properties of active pharmaceutical ingredients API make them highly sensitive to their environment, making API manufacturing and production a tightly regulated field.

Active pharmaceutical ingredients (API)

Pusher centrifuges are continuously operating filter centrifuges and can have several basket stages depending on the application. Widely used for processing salts, fertilizers, but also plastics, soda and cellulose.


<h2>Continuous solids throughput under the toughest conditions</h2>
Pusher centrifuges from Ferrum are continuously operating filter centrifuges that are based on the very successful Sulzer Escher Wyss design. The slurry is fed continuously to the product acceleration disc via the filling pipe. The solids are transported out of the centrifuge basket into the discharge channel, from where they leave the pusher centrifuge. The cake is cleaned in the centrifuge by adding washing liquid on to the solid cake.

Various models have been developed with basket sizes ranging from 230mm to 1200mm. The most common applications are developed in agricultural and petrochemical industries, such as filtration for obtaining zinc sulphate, lysine, nitrocellulose, sea salt, sodium carbonate, urea, Glauber’s salt, potassium chlorate, potassium nitrate, linters and so on.

Pusher centrifuge

Vertical Bottom discharge Centrifuges work discontinuously, discharging the solids to the bottom. They are suitable for the demanding continuous operation in the chemical and fine chemical industry or for complex pharmaceutical applications.


<h2>Efficient and reliable process cycles with low vibration</h2>
The Vertical Scraper centrifuges VBC (Vertical Bottom discharge Centrifuge) from Ferrum include many application areas in the solid-liquid separation due to the modularity and the comprehensive range of optional equipment. The solid-liquid separation is effected discontinuously in a sequence of specific process steps. The individual process steps last from a few minutes to several hours depending on the characteristics of the product.

The most common applications are in the paint industry with pigments; herbicides, insecticides and carbofuran in the agrochemical industry; antibiotics, vitamins, APIs and other intermediates in the pharma industry; and plenty of applications in the food industry.

Vertical scraper centrifuges

A vertical peeler centrifuge is used to separate solids, usually to separate fine particles from suspension liquid feed mixtures in the pharmaceutical industry, where the scrapped solids are discharged through the bottom of the centrifuge vessel.


<h2>Excellent inspection outside and below the centrifuge basket</h2>
The Vertical Peeler centrifuge is a new development of the centrifuge type VBC-S (Vertical Bottom discharge Centrifuge - Swivel Open Housing) from Ferrum and it was specially designed for use in the demanding pharmaceutical industry.

Pharmaceutical centrifuges are used for products that can be filtered with solids concentrations from 2 w% and particle sizes of minimum 4 μm. The continuous operation of centrifuge allows all process steps are carried out simultaneously, increases the overall throughput.

The most common applications in the pharma industry are in Active pharmaceutical ingredients (APIs), antibiotics, salicylic acid, pharmaceutical intermediate products, etc.

Vertical peeler centrifuge

Discharge solids vertically upward through manual action, optionally using a filter bag or a special suction device.


<h2>Optimally designed controls for easy, efficient operations</h2>
The top discharge centrifuges from Ferrum include many application areas in the solid-liquid separation due to the modularity and the comprehensive range of optional equipment. The applications of the vertical top discharge centrifuge, range from pilot plants, small-quantity production to production applications in the chemical and pharmaceutical industries.

Vertical top discharge centrifuge

The system is perfectly suited for pilot plants as well as small-quantity productions in the fine chemical and pharmaceutical industries.


<h2>Compact and mobile centrifugation</h2>
The mobile pilot plant centrifuge from Ferrum, combines centrifuge, control and drive components as well as inertisation system in one mobile turnkey unit. The system is perfectly suited for pilot plants as well as low volume production in the fine chemical and pharmaceutical industries. The solids are discharged vertically upward manually or using a filter bag.

Mobile pilot plant centrifuge

For transferring highly active pharmaceutical ingredients (HAPI) without contamination from the isolator centrifuge to the next process step (e.g. vacuum tray dryer).


<h2>Simple and efficient handling within the isolator</h2>
The VTC isolator centrifuge from Ferrum is designed especially for the use in an isolator.

This allows the operator contamination-free transport of toxic active pharmaceutical ingredients (HAPI) from the centrifuge to the next process step (e.g. vacuum dryer).

The solids are discharged from the basket either manually or by means of a lifting device.

The system is Suitable for pilot plants as well as small production quantities in the pharmaceutical industry.

Isolator centrifuge

For slurries difficult to discharge, a scraper can improve process reliability, efficiency, and operating cost. At reduced speed, the scraper knife swings into the filter cake and scrapes out the product vertically downward via the discharge chute.


<h2>Easy to access centrifuge for the best inspection</h2>
The HPZ 630-1600 range from Ferrum for pharmaceutical centrifuges HPZ range from pilot plants and low volume production to production applications in the demanding pharmaceutical industry. Ferrum pharmaceutical centrifuges are used for products that can be filtered with solids concentrations from 2 w% and particle sizes of min. 4 μm.

When expecting the processing area and the internals, the entire housing is swiveled open. An optional front door further eases and improves inspection. The centrifuges can be operated in an automatic, semi-automatic, manual or service mode. With the Horizontal pharmaceutical scraper centrifuge, a wide range of production recipes can be saved.

Horizontal pharmaceutical scraper centrifuge

For slurries difficult to discharge, a scraper can improve process reliability, efficiency and operating cost. At a reduced speed, the scraper knife swings into the filter cake and scrapes out the product vertically downward via the discharge chute.


<h2>High solids throughput with low energy consumption</h2>
The Ferrum HCZ 1000 and 2000 centrifuges were purposely designed for high throughputs and continuous operation under the toughest conditions in the chemical and fine chemical industry. The design features are robust and very reliable in accordance to the latest standards and directives. The centrifuges are built for permanent operation under the toughest conditions.

The Horizontal chemical scraper centrifuge is widely tested for herbicides and pesticides, special applications such as ABS, iron sulphate, melamine and so on can also be developed.

Horizontal chemical scraper centrifuge

The laboratory-scale active freeze-drying is used for dehydrating high-value products that are too sensitive for conventional drying processes. The product is dried by freezing and subsequent sublimation of ice formation, typically in vacuum and at low temperatures, in a small laboratory and pilot plant scale, enabling a smooth transition to the production plant.


<h2>Start innovating with freeze-drying technology</h2>
The 1-liter laboratory-scale freezer dryer from Hosokawa Micron is quicker and less labor-intensive than traditional tray-type freeze dryers. It offers the possibility of producing loose and free-flowing powder at low temperatures and low pressures, all in one vessel. Ideal for testing and simulating processes, the lab unit is "plug and play", including controls and all necessary equipment for reliable operation in your laboratory environment. Ideally suited for pharmaceuticals like antibiotics, collagens, APIs and electrolytes; food industry and special materials like nanomaterials, polymers, ceramics, pigments, fillers, limestone, catalysts, glass powder and salts.

&nbsp;

Laboratory scale active freeze dryer

A multipurpose unit in the research and development field. Some of the most common applications are galenic formulation, freeze drying experimentation, taxidermy, underwater archaeology, aliquot preservation,  diagnosis and other research.


<h2>Start your research with this multipurpose high-performance device</h2>
The LyoQuest laboratory, multipurpose and R&amp;D freeze dryer from Telstar Life-Sciences has been designed as a multipurpose unit for the research and development field. It is a small freeze dryer, more compact than most but in spite of its small size, its capacity is quite unbeatable. A state-of-the-art control system and a range of specially designed accessories make the LyoQuest a benchmark in its category.

The unit's design offers the best performance in the least possible space. Suitable for laboratories: compact and easy to install, solidly designed laboratory equipment. On a functional level, cooling management ensures optimum performance.

Multipurpose and R&D freeze dryer

Freeze dryer designed for aseptic and small-scale production of high-value products.


<h2>Industrial freeze dryer in a compact envelope</h2>
Lyotris from Telstar Life-Sciences is a lab scale production freeze dryer designed for the production of small batches of high-value pharmaceutical products. With a 1m2 loading surface and capacity for approximately 1,600 10R-type vials or 30 liters of bulk product. It has been specially designed for aseptic production in vials or in bulk and its novel fascia and door design provides easy isolator integration.

The GMP laboratory freeze dryer comes with all  the necessary components for an automatic cleaning (CIP) and steam sterilization (SIP) processes, filter integrity testing (WIT) and also incorporates an advanced SCADA system which includes Telstar's patented ‘Lyometrics' system; providing advanced real-time information on the freeze-drying process.

GMP laboratory freeze dryer

The pharmaceutical and bioprocess industries need filtration processes of particularly high quality to ensure the containment of potentially hazardous substances and avoid product contamination. Experienced biopharmaceutical manufacturers know that equipment designed for general industry use often falls short of the tight quality and hygienic standards of our industry and that producers who embrace high quality pharmaceutical grade equipment will have an advantage over competitors.
<h2>A pharmaceutical grade filter system with maximum separation and complete filter cake removal and drying</h2>
Mavag AG's smaller scale and focus on their tradition of Swiss craftsmanship ensure the impeccable product quality that customers need. The company's Filter Dryer system is an agitated pressure filter with added features that make it particularly well suited to the pharmaceutical and bioprocess industries. The unit consists of a single plate filter that effectively removes solids from the processed mixture and forms a filter cake. The filter caked can be re-suspended in a liquid slurry using the magnetically driven agitator. This allows the filter cake to be discharged without exposing the interior of the system to the surrounding environment—reducing contamination and exposure risk. The unit also includes a heated vessel and agitator, a solvent recovery system, a vacuum generator, and a dust filter. These added features allow for very thorough washing of the filter cake and complete removal of solvent from the filter cake in a completely enclosed process step.  This makes the units extremely valuable to process that require excellent containment and avoidance of cross contamination as are commonly found in the pharmaceutical and bioprocess industries.

Filter dryer

Drying vessels that are simple, reliable, and easy to maintain increases product quality and process efficiency in this highly sensitive industry. Experienced biopharmaceutical manufacturers know that equipment designed for general industry use often falls short of our industry's tight quality and hygienic standards and that producers who embrace high-quality pharmaceutical-grade equipment will have an advantage over competitors.
<h2>A spherical agitated dryer with uniform drying, complete product discharge, and easy maintenance</h2>
Mavag AG's smaller scale and focus on their tradition of Swiss craftsmanship ensure the impeccable product quality that customers need. The company’s Mavaspher spherical dryer line is spherical agitated dryers that use a magnetically coupled agitator blade to stir fine chemical products inside of a machined spherical vessel for the pharmaceutical and biotech production industries. The vessel is flanged and hinged at the equator for easy opening for inspection, cleaning, and maintenance. A spherical disk valve at the lowest point in the sphere provides effective product discharge. The agitator is eccentrically mounted to aid with product discharge and provided complete mixing and gentle drying to the contained products. The shape of the agitator blades is carefully controlled to maintain a small gap between the blades and the vessel walls. Options are available to convert the agitator to a chopper are available according to the customer’s needs. The hinged, spherical shape allows the vessel to be opened up fully for cleaning and maintenance access easily. It also ensures consistent product mixing and even exposure of powders to the agitator blades and discharge valve.

Spherical dryer

Conventional dryers are inefficient and can lead to significant mechanical and thermal stress on sensitive products. Non-uniform mixing can lead to lump formation and increased processing time. Vacuum dryer with eccentric agitator is designed to dry wet flowing powders from filtration and centrifuging processes.


<h2>Vacuum dry efficiently in an agitated paddle dryer</h2>
Planex® system from Italvacuum is a special horizontal vacuum paddle dryer with an eccentric agitator which revolves around its own axis while rotating tangentially to the drying chamber. It is ideal for drying wet feeds from filtration and centrifuging processes. Planex® is ideal for the production of active pharmaceutical ingredients (API), fine chemicals and intermediates. The efficient agitator action ensures perfect mixing and consumes three times less energy than conventional dryers. It also reduces the mechanical and thermal stress on the products which is important for delicate and temperature-sensitive applications. The tangential movement of the agitator prevents lump formation. Suitable for both crystalline and amorphous products, Planex® has a short cleaning downtime and complies with US FDA standards and cGMP regulations.

&nbsp;

Horizontal vacuum dryer with eccentric agitator

Powdered products tend to agglomerate during vacuum drying. This adds an additional step to the production process where the dried product is milled to produce a uniform grain size. Lumps may also prolong the drying process and compromise product quality.


<h2>Industrial vacuum dryer for moist masses after centrifugation or filtration processes</h2>
The CRIOX System from Italvacuum is a vacuum dryer with two sets of electric lump breaker blades inside the rotary double-cone chamber. These blades prevent product agglomeration, increase the product surface area exposed to evaporation and enhance mixing effectiveness. This results in a powder with a controlled grain size that is ready for bagging. The lump breakers significantly reduce drying time and deliver the lowest possible residual humidity, unattainable with other systems. The rotary vacuum dryer allows operation at lower processing temperatures thus preventing thermal degradation of sensitive products. It offers rotating speed control, scheduling of operating cycles, constant torque with changing speed, absorption control and ventilated cooling.

Rotary vacuum dryer

Agitated vacuum dryers can be difficult to clean which makes them unsuitable for multi-product applications. The presence of the agitator can make cleaning jobs tough resulting in production delays or compromised product quality.
<h2>Vacuum dry wet powders in an agitated paddle dryer</h2>
CosmoDry® System is an innovative, horizontal paddle vacuum dryer from Italvacuum. It features a concentric agitator fitted with a heated shaft that can be completely dismantled for easy internal cleaning, maintenance, and inspection. CosmoDry systems are ideal for drying of wet powders in the production of pharmaceuticals, fine chemicals, cosmetics, food ingredients and additives. CosmoDry eliminates friction points to reduce mechanical and thermal stresses on the product. Designed for quick, easy and complete product unloading, CosmoDry is ideal for multi-product applications. It complies with the cGMP and ATEX regulations.

Horizontal paddle vacuum dryer

Vacuum drying is used to remove moisture from sensitive materials. Drying small batches in the laboratory for R&amp;D work or removing moisture from high-potency active pharmaceutical ingredients requires careful handling and control.
<h2>Vacuum dry small batches and HPAPI's</h2>
LaboDry from Italvacuum is a laboratory-scale, vacuum tray, drying oven designed to meet small batches and high potency API production requirements. It features a separate cells construction and has been designed for glove box installation. It can be fitted with skid-mounted auxiliary accessories. LaboDry is available in in AISI 316L (1.4404), AISI 904L (1.4539) and ALLOY C-22 (2.4602) construction to meet the requirements of appropriate material for product contact. LaboDry is ideal for laboratory use and the pharmaceutical industry.

Laboratory-scale vacuum tray drying oven

Fluid bed drying is a pharmaceutical process carried out to reduce the humidity and achieve the required moisture content in the granules or powders. It also applies binders or granulation liquid to facilitate the agglomeration of wet mass before further processing. When drying pharmaceutical granules, it is essential to avoid over-drying as this could result in significant wearing down, leading to product loss. To prevent losses and poor product quality, you need a fluid bed dryer to handle continuous operation.
<h2>An efficient, robust solution to dry pharmaceutical compounds</h2>
The Fluidized Bed Dryer from Romaco Tecpharm uses the drying process to reduce the moisture content in the granules. It can be configured as a dryer, granulator, and coater. It can thus dry wet granulate, top drive granulation, and bottom spray coating. It has a capacity from 30 L to 1,540 L, with other dimensions being available on request.

The fluid bed dryer for pharmaceutical solid dosage form is constructed with an in-wall design concept. It is equipped with a side-valve for automatic loading from the high shear mixer granulator. For the drying process, hot air is passed through a vacuum generated inside the machine. The wet solids rise from the bottom and are suspended in a current of air, remaining in a fluid state. The heat transfer and the low moisture content of the air in direct contact with the wet granule allow the evaporation of the water or solvents, reducing their humidity.

The equipment has a top spray that helps in carrying out the granulation. Next, the movement of the powder in a fluidized state is combined with the spraying of a binder solution. This combination allows increasing the particle sizing, generating a granulate. Finally, the coating process is carried out by combining the spraying of the coating suspension on the micro granules in a fluid bed movement.

Fluid bed dryer for pharmaceutical solid dosage form

It is rather difficult to successfully produce a pharmaceutical solid dosage forms with the desired properties such as size, morphology, hardness and friability. You need a solution that can transform fine heterogeneous powders into homogeneous blend of granules with bigger size and higher density in a short time and with repeatability. Wet granulation is carried out to convert fine and cohesive active ingredient and excipients, into more uniform, free-flowing granules that are optimised for downstream processing.
<h2>Achieve uniform particle size distribution for wet granulation</h2>
The High Shear Mixer Granulator from Romaco Tecpharm is configured to optimize the wet granulation process. It is used to turn a fine-powder heterogeneous mixture into a uniform granulation, with increased particle size and higher density.

The equipment offers you proper flow and compactness while having a shorter operational time. It can handle capacities ranging from 25 L to 1,400 L.The bottom impeller and the side chopper enables the intensive mixing in a short period of time. In addition, the equipment uses a synchronized system to avoid extrusion effect.

The high-shear granulator for drug formation processes the solid material down to the desired particle size, and the mixture is then pumped to the fluid bed dryer where the moisture is removed, leaving behind the granular product. During the process of wet granulation, the constituents of the oral solid dosage form blend are combined, along with agglutinative solution, to form granules with a homogenous composition.

Industrial high shear mixer granulator for drug formation

Pharmaceutical industries employ several processes including drying, coating and granulation to create high-quality granules. Manufacturers can benefit from a single system that can complete all of these tasks simultaneously, increasing production yield without sacrificing the quality of the final product.


<h3>Coating, granulation, and drying granules by tangential fluid bed method</h3>
The Fluidized Bed System BFS from Bohle, is a system that can perform multiple processes such as coating, granulation, and drying to turn fine solids and dry powders into granules. The cone is equipped with a specially slotted air distributor plate which allows complete fluidization of particles while the tangential motion helps in achieving a uniform coating without the particles adhering to one another. Due to a relatively low fluidization height, the system does not require a high-volume expansion saving costs and production floor space.

The system can also be equipped with an online moisture measurement system using NIR technology to precisely identify moisture levels during the granulation and drying. The BFS has at least 6 filter elements that can be cleaned separately and ensure good uninterrupted airflow. To make it simple to use, the entire system is PLC controlled.

Fluidized bed system for the granulation and drying of pharmaceuticals

Pharmaceutical laboratories need compact equipment to handle and produce small amounts of granules from a mixture of wet and dry elements for R&amp;D applications. Furthermore, the granulation process requires short residence times in drying the products to easily identify and remove the defects without discarding the entire batch.


<h2>Automatic feeding, granulating, and quick drying of pharmaceutical  products</h2>
The QbCon 1 from L.B. Bohle is a continuous wet granulating and drying system for pharmaceutical laboratory scale applications. The system performs three processes: feeding, granulating, and drying. It features a twin screw granulator with a hinged barrel for easy access to its parts. The unit comes with a multi-position feeder and interchangeable ports, ensuring accurate gravimetric feeding of dry powder and using a pulsation-free pressurized feeder for granulation liquid.

The wet granules are gently dried by a moving fluid bed that provides short residence times and consistent product output. Its narrow residence time distribution allows easy traceability from the initial product to the final tablet or vice versa. The drying process parameters, such as airflow, temperature, and conveying speed, can be controlled and adjusted according to product requirements. The system allows for sampling wet and dry granulations without interrupting the ongoing processes. The system also has an innovative filter cleaning system to prevent clogging for longer hours of operation. The unit also features a complete WIP (Wash-in-Place) cleaning.

Continuous wet granulator and dryer for R&D

Freeze-drying is both a time- and energy-consuming process. In addition to the drying itself, loading the trays in and out of the dryer manually also requires a lot of time. Therefore you need to focus on process and loading efficiency.


<h2>Freeze-dry your berries, coffee, and pharmaceuticals quicker with a higher throughput</h2>
The Quasi-Continuous Freeze Dryer (QCF) from Bucher Merk is for freeze-drying goods in the food and pharmaceutical industry in a semi-continuous way. It has an easy tray-loading solution with trolleys suspended from a top-rail system which makes the product handling process easier and faster compared to fully manual loading.

What is more, it is suitable for batches starting at 200 kg and can go up to 3,000 kg. The QCF, allows you to dry products gently and efficiently while saving on energy costs. The system is unique because it utilizes both contact (from below) and radiant heating (from above) for faster processing compared to traditional methods. You can achieve high product quality by a controlled drying profile, limiting the maximum product temperature and in the same shortening the overall drying time.

It comes with vacuum and heating or cooling systems specifically designed to utilize preferred energy sources and provide the optimum balance between short batch times and energy savings. You have the option to include features such as product weighing, continuous drying observation with cameras, emergency cooling, automatic trolley loading/unloading, and cleaning systems in combination with up- and downstream processes.

Semi-continuous freeze dryer with easy-loading

In the pharmaceutical and chemical industries, developing sterile products that require precise drying and mixing processes is crucial. The challenge lies in achieving gentle drying of varied materials, from moist powders to wet suspensions, without compromising product integrity.
<h2>Dry, mix, and react with precision under vacuum</h2>
The 3-in-1 Vertical Vacuum Dryer and Mixing Reactor by Amixon is a highly versatile solution designed to handle dry, moist, and viscous materials at variable filling levels. The system features a spiral mixing blade that initiates a three-dimensional flow, ensuring thorough blending and efficient drying. This vacuum and pressure-tight unit is fully temperature controlled with heating options such as steam, thermal oil, or water for the mixing vessel, arms, and spiral blade. Compliance with FDA and 3-A Sanitary Standards makes it suitable for sterile operations, meeting EHEDG requirements. Ideal for processes that require deagglomeration, the unit can be fitted with high-speed cutting rotors. Its compact design and top-driven shaft mechanism reduce the space needed while maintaining high standards for surface finish, catering to pharmaceutical and sanitary requirements.

Vertical vacuum dryer and mixing reactor

In diagnostic kit production or tissue banking, freeze drying is essential for maintaining the integrity and extending the shelf life of sensitive biological materials. Challenges arise when trying to balance efficiency, precision, and footprint in laboratory or cleanroom settings.
<h2>Compact customizable freeze drying solution</h2>
The VirTis Ultra 50L and 35L Pilot-Production Freeze Dryers from ATS Scientific Products are versatile freeze-drying solutions suitable for pilot and small-scale workloads. These dryers feature a space-saving, compact design and can be customized with up to 15 shelves, various control systems, and temperature and vacuum sensors, allowing you to tailor the system to your specific needs. With shelf temperatures as low as -70ºC and condenser temperatures down to -85ºC, they handle various applications—from high moisture products like vials and bulk liquid APIs to low moisture items such as diagnostic kits and tissue samples. Besides, the front-facing vacuum pump simplifies maintenance. Available control systems include the Merlin and LyoS 2.0™.

Pilot-production freeze dryers for diagnostic kits and tissue banking

In pharmaceutical and biotech production, achieving efficient and consistent drying of sensitive materials can be a challenge. Many labs require tailored setups to handle diverse products, stringent regulations, and specific operational capacities.
<h2>Customize freeze-drying to your exact needs</h2>
The VirTis Benchmark Production Freeze Dryer from SP Industries is designed to meet the unique demands of different laboratory and production environments. Engineered from premium 316L stainless steel, it offers customizable options to address specific needs without compromising on quality. The system allows you to customize shelf sizes, configurations, and control packages. It features 21 CFR Part 11 compliant software, making it suitable for highly regulated environments. With over 200 units installed worldwide and a reputation for dependability, this freeze dryer is ideal for processing diagnostic kits, active pharmaceutical ingredients (API), nutraceuticals, and more. The system employs Lyos 2.0™ control, which facilitates simplified scaling up from pilot to production stages. Optional clean-in-place (CIP) solutions are also available, making maintenance straightforward and efficient.

Customizable production freeze dryer for pharmaceuticals

In pharmaceutical production, ensuring the purity and quality of polymeric microspheres after solvent extraction is crucial. Challenges often include efficient classification, drying, and maintaining sterile conditions while reducing operational costs.
<h2>Classify, wash, and dry polymeric microspheres</h2>
The Microsphere Refiner (MSR) by Austar is utilized for the classification, filtration, washing, and drying (freeze-drying) of polymeric microspheres post-solvent extraction. It offers a high yield of up to 90% and integrates all necessary processes into a single piece of equipment, including classification, washing, drying, sampling, and discharge. The MSR features automated process control and can integrate with a Process Skid for complete automatic production. Its efficient classification is achieved through both horizontal and vertical filtration methods, while drying benefits from jacket heating and cooling. The refined design includes an optimized tilt discharging mode. The MSR is scalable to different production sizes, ranging from laboratory (gram scale) to commercial production (up to 25 kg). Additionally, it can be configured to produce without sterile isolation or freeze-drying systems, lowering operation and maintenance costs.

Microspheres process equipment for classification, washing, drying

In pharmaceutical manufacturing, ensuring the stability and shelf-life of active pharmaceutical ingredients (APIs) is crucial. Freeze-drying is a method often used to address these challenges, particularly in the production of vial and panel-packed APIs, by preserving the physical and chemical properties of the products.
<h2>Ensures product stability through advanced freeze-drying</h2>
The LYOCORE freeze-dryer from Austar is designed to meet the rigorous demands of commercial API production. Manufactured according to European quality standards and based on the Quality by Design (QbD) concept, this freeze-dryer ensures compliance with cGMP and FDA requirements. It offers a flexible and high-performance solution for preserving APIs in both vial and panel-packed formats. Key features include an advanced freeze-drying system capable of maintaining product integrity through precise control of temperature and pressure. Furthermore, the system provides efficient moisture removal, ensuring long-term stability and shelf-life of the products.

Commercial freeze dryer for pharmaceutical Api production

In fields such as pharmaceuticals, nanotechnology, and materials science, creating uniform, submicron particles is essential for drug delivery, catalysis, and advanced material production. Conventional drying methods often struggle with losses and inefficiency when working with minimal sample sizes.
<h2>Produce submicron particles with high yields</h2>
The Nano Spray Dryer B-90 HP from Buchi enables the generation of small particles, ranging from 200 nm to 5 μm, with an impressive yield of up to 90%. This system is designed to process sample volumes as small as 2 mL, minimizing product loss. It features a piezo-electric spray head and a high-voltage particle collector, both of which contribute to optimal particle recovery. The system supports both aqueous and organic solvents, and its gentle drying conditions help preserve the integrity of sensitive compounds. With an evaporation capacity of up to 0.2 L/h for water and higher for organic solvents, it offers unmatched productivity in laboratory settings. The Nano Spray Dryer B-90 HP is ideal for applications in pharmaceuticals, nanotechnology, and materials science, where precise particle size and high product recovery are critical.

Nano spray drying system for pharmaceuticals and nanotechnology

In small-scale commercial operations and research and development settings, there is often a need to efficiently freeze dry a variety of biological, pharmaceutical, nutritional, and general food products. This requires a solution that offers consistent performance, versatility, and ease of relocation when necessary.
<h2>Efficiently freeze dry small commercial batches</h2>
The FD100GPC Freeze Dryer by Cuddon Freeze Dry is a versatile solution for small commercial batches and research and development projects. With a 100kg ice capacity and a 9.1m2 shelf area, this plug-and-play model can handle a variety of products, from biological specimens to pharmaceuticals and general food items. The freeze dryer’s compact design allows for easy relocation, making it ideal for facilities that require flexibility. It features optimal shelf temperatures ranging from -35°C to 70°C and an ice condenser temperature of -40°C. The unit is capable of sublimating 100kg of ice in under 24 hours, with an average yield of 20kg of dry product per cycle. The FD100GPC has a peak power requirement of 7.5kW and an estimated energy consumption of 1.5kWh per kilogram, ensuring cost efficiency. Built with food-grade anodized aluminum product trays and a single door product chamber, the FD100GPC offers easy maintenance and robust performance, making it well-suited for a wide range of industrial applications.

General purpose freeze dryer for small commercial batches

In the pharmaceutical industry, particularly for producing active pharmaceutical ingredients (APIs) like high potent cytostatic drugs, precise filtration, washing, and drying processes are critical. Managing these stages efficiently while maintaining product integrity can be challenging.
<h2>Handle filtration, washing, and drying efficiently</h2>
The Filter Dryer RGFD 3.0 – 2.4602 by De Dietrich Process Systems is designed to streamline the production of high-value pharmaceutical products. Specialized for handling slurries of APIs and mother liquors, this system ensures thorough filtration, effective washing, and consistent drying. It features a double chamber isolator for product discharge and an additional pusher port isolator to facilitate heel recovery and sampling. Capable of providing a 3D model layout upon proposal submission, this Filter Dryer integrates seamlessly with existing setups and maintains product integrity through its advanced design, making it ideal for pharmaceutical applications.

Industrial filter dryer for high potent Api production

In the pharmaceutical and fine chemical industries, precise solids washing and separation are critical tasks. Operators often face challenges such as cross-contamination risk, time-consuming processes, and exposure to hazardous materials.
<h2>Manage solids separation and drying efficiently</h2>
The Agitated Nutsche Filter and Filter-Dryer by De Dietrich Process Systems is designed to meet stringent industry requirements for solid-liquid filtration and drying. This system excels in various tasks including filtration, reslurry washing, and drying under vacuum or convection. It supports multiple filter media options such as cloth, single layer metal screen, and multi-layer sintered metal, enhancing its versatility. A significant feature is the side discharge valve with metal-to-metal seals, eliminating issues with o-rings and ensuring a pressure-tight, cleanable design. The heated filter plate allows efficient heat transfer through all contact surfaces, enhancing drying capabilities. Additionally, the Gas Knife system facilitates total discharge by directing gas streams through small nozzles on the agitator blade. The filter-dryer is constructed from various materials such as 316L stainless steel and Alloy 20 for optimal compatibility with different applications. Designed by De Dietrich, the unit integrates seamlessly into pharmaceutical environments, and is available in configurations to handle highly potent materials with its rigid discharge glovebox and ergonomic design. For processes requiring sterile conditions, SIP capabilities are included to eliminate internal dead spaces.

Agitated nutsche filter and filter-dryer for pharmaceuticals

In the pharmaceutical industry, manufacturing of low dosage, highly potent products poses significant challenges. Achieving minimal batch sizes without compromising on mixing homogeneity is essential for both early phase development and full-scale production.
<h2>Combine batch and continuous manufacturing processes</h2>
The Mini Batch Blender GBM 10 P by Gericke is designed to blend for continuous manufacturing of solids. It offers a semi-continuous approach, bridging the advantages of traditional batch processes with those of continuous manufacturing. The system allows for minimal batch sizes, ranging from less than 1 kg to 3 kg, and accommodates production rates of 0 to 20 kg/h without requiring scale-up. This flexibility makes it suitable for low dosage, highly potent products. The blender is equipped with advanced features like high containment and Wash-in-Place (WIP) capabilities, ensuring minimal operator exposure and easier cleaning processes. Suitable for integrating Process Analytical Technology (PAT), the system is designed for simple feeder startup and material tracking without the need for Residence Time Distribution (RTD) modeling.

Mini batch blender for pharmaceutical solids

In pharmaceutical and fine chemical manufacturing, drying of freely flowing and sensitive ingredients is a critical step. Traditional drying methods often fail to meet stringent cGMP and FDA guidelines, posing challenges in maintaining product integrity and efficiency.
<h2>Ensures uniform and efficient drying</h2>
The Mavadry by GMM Pfaudler is a high-performance rotary vacuum paddle dryer designed to provide efficient and uniform drying of pharmaceutical ingredients and fine chemicals. Key features include a special heated airfoil blade integrated with a high-speed chopper, which aids in both wet and dry chopping in combination with a stator for milling. Additionally, the unit has a high-torque hydraulic drive that allows for a flexible degree of filling and adapts to a wide range of physical product characteristics. The minimal clearance between the vessel wall and agitator ensures optimal heat transfer and uniformity. The entire vessel is covered by a jacket, enhancing heat transfer. Available in materials such as stainless steel, Hastelloy, and special alloys, the Mavadry meets stringent cGMP and FDA guidelines. Capacities range from 100 to 4000 liters, making it adaptable for various production scales.

Rotary vacuum paddle dryer for pharmaceutical ingredients

When dealing with Active Pharmaceutical Ingredients (APIs), precise and efficient drying methods are essential. The need is to ensure compliance with cGMP and FDA standards while achieving consistent drying that is both energy-efficient and maintains the integrity of the API.
<h2>Ensures efficient drying and compliance</h2>
The Mavapad® by GMM Pfaudler is a versatile and energy-efficient vacuum paddle dryer designed for use with Active Pharmaceutical Ingredients and other pure chemistry applications. It offers a large heat transfer area on the vessel body and agitator, facilitating faster drying times. Unlike dryers with dished ends, its flat ends minimize heel volumes and improve emptying characteristics. The full door opening allows for easy cleaning and validation, ensuring compliance with stringent regulatory standards. Operating at lower costs compared to other dryers, Mavapad® comes with multiple base material options including stainless steel, Hastelloy, and special alloys. The design can be adapted for sterile or clean room environments with a stainless-steel partition wall. Additionally, GMM Pfaudler engineers provide support for optimizing and sizing the system to meet specific process requirements.

Vacuum paddle dryer for active pharmaceutical ingredients

Drying Active Pharmaceutical Ingredients (APIs) and fine chemicals while complying with cGMP and FDA guidelines is a stringent requirement faced by manufacturers aiming for consistent and high-quality end products.
<h2>Ensures uniform drying with efficient heat transfer</h2>
The MAVASPHERE® by GMM Pfaudler is a spherical vacuum dryer designed specifically for APIs and fine chemicals, offering excellent performance across various filling capacities. The dryer features minimal clearance between the vessel wall and agitator, which enhances uniform drying. To optimize heat transfer, the entire vessel is jacketed. Its eccentrically top-mounted agitator ensures uniform mixing and gentle drying. The design includes a discharge at the lowest point, ensuring complete product evacuation. Construction materials include stainless steel, Hastelloy, and special alloys, ensuring durability and compliance with industry standards. Additional features such as an effective lump breaker, quick discharge spherical disc valve, and minimal product hold-up make the MAVASPHERE® a reliable choice for industrial drying needs.

Spherical vacuum dryer for Apis and fine chemicals

In the pharmaceutical industry, ensuring that Active Pharmaceutical Ingredients (APIs) are dried efficiently and in compliance with strict regulations is crucial. Traditional drying methods often struggle to meet these high standards while optimizing energy consumption and minimizing operational costs.
<h2>Efficiently dry Apis with cgmp and Fda compliance</h2>
The Vertical Conical Dryer (VCD) from GMM Pfaudler is an energy-efficient system specifically designed for drying Active Pharmaceutical Ingredients (APIs) while adhering to cGMP and FDA guidelines. It effectively uses both static and dynamic heat transfer areas to ensure efficient drying. Its vertical installation and bottom discharge design result in lower heel volumes, facilitating better emptying characteristics. The VCD can handle a wide range of filling capacities, allowing for a good turndown ratio. Additionally, its compact design results in a lower footprint and reduced operating and maintenance costs when compared to other drying systems. Optional accessories include a lump breaker, sampling system, condenser, receiver, and vacuum pump. Available in materials such as stainless steel, hastelloy, and special alloys, the VCD is also suitable for sterile/cleanroom areas through in-floor installation that isolates the drive unit from the process area.

Vertical conical dryer for pharmaceutical ingredients

In the pharmaceutical and chemical industries, the filtration of delicate and difficult-to-filter products is a significant challenge. Ensuring high product yield and minimal residual moisture during the filtration process is critical, particularly when dealing with high-potency active pharmaceutical ingredients (APIs).
<h2>Hermetically sealed for precise and efficient filtration</h2>
The Inverting Filter Centrifuge HF by Heinkel is designed to meet the demands of challenging filtration processes. Featuring a hermetically closed design, this centrifuge ensures contamination-free and automated operation. Its unique inverting mechanism allows for a residual heel-free product discharge, making it optimal for high-potent API products. The centrifuge integrates pressure added centrifugation (PAC) to significantly reduce residual moisture compared to conventional filtration methods. Available in multiple models ranging from the HF 300.1 to HF 1300.1, it offers capacities from 6.5 liters to 350 liters and centrifugal forces up to 1,500 x g. The units are constructed to handle demanding applications, characterized by their robust design and minimal installation within the housing and basket, ensuring the highest possible product yield.

Inverting filter centrifuge for high-potent Api products

Pharmaceutical production requires equipment that ensures optimal cleanability, complies with stringent regulatory standards, and guarantees efficient drying performance. The challenge lies in meeting these high standards while maintaining ease of inspection and maintenance.
<h2>Ensures compliance with cgmp and Fda guidelines</h2>
The COMBER Pressofiltro® Series PF 100 - PF 10000 is a pharmaceutical-grade nutsche filter dryer designed to meet the rigorous requirements of pharmaceutical production. These units adhere to cGMP and FDA guidelines, ensuring high standards for cleanability and product safety. Featuring an openable filter base, the system allows easy access for cleaning and inspection. Interchangeable filter plates provide flat, homogeneous surfaces for effective cleanability. The design includes multilayer and conventional filter materials, optimizing drying performance through a special agitator and large heat exchange areas. External, interchangeable double mechanical seals come in various types including dry running, non-contacting lift-off, and liquid lubricated seals. The product-wetted components are available in stainless steels and nickel-based alloys like Hastelloy C22, ensuring durability and resistance to corrosion. The equipment is controlled via a sophisticated control cabinet with PLC and HMI touchscreen, and can integrate with DCS interfaces. It operates within a wide temperature range of -10 to 150°C and pressure range of -1 to +4 barg, making it versatile for various pharmaceutical applications.

Pharmaceutical filter dryer

In pharmaceutical and fine chemical manufacturing, delicate ingredients require careful and controlled drying processes to maintain their integrity. Ensuring compliance with stringent regulatory guidelines is crucial for product quality and safety.
<h2>Efficiently dry sensitive ingredients with precision</h2>
The Pharmadry vacuum paddle dryer by Heinkel (Comber) is designed for drying sensitive pharmaceutical ingredients and fine chemicals with short drying times. Conforming to cGMP and FDA guidelines, it features an agitator supported at the rear with an externally exchangeable mechanical seal, ensuring minimal contamination risks. The entirely welded agitator design eliminates bolts and pockets, allowing for thorough cleaning with CIP systems. With a minimal build depth, the Pharmadry offers excellent accessibility for inspection and cleaning. Available in aseptic or steam sterilizable versions, this dryer incorporates a double mechanical seal, either dry running lift-off type or liquid lubricated seals, enhancing its versatility and reliability. Usable volumes range from 50 to 4,000 liters, with a design temperature of -10 to 150°C and a design pressure from -1 to +6 barg, making it suitable for various applications.

Horizontal vacuum paddle dryer for sensitive pharmaceutical ingredients

In industries like pharmaceuticals and fine chemicals, drying heat-sensitive and highly viscous products often presents significant challenges. Traditional methods can result in product degradation due to excessive heat or uneven drying. A vacuum pan dryer can address these issues effectively.
<h2>Optimizes drying of sensitive, viscous products</h2>
The Comber Turbodry® agitated vacuum pan dryer, supplied by Heinkel Group, excels in drying sensitive, pasty, and other difficult products that become highly viscous during the drying process. The unique design adheres to cGMP and FDA guidelines, ensuring compliance for pharmaceutical and fine chemical applications. Its simultaneous axial and radial agitator movements achieve uniform mixing of the product mass, preventing the formation of lumps. This ensures the shortest possible drying times. A double mechanical seal system, which is externally interchangeable and can be either dry running, non-contacting lift-off, or liquid lubricated, enhances reliability. Constructed from high-quality materials such as stainless steel and Hastelloy C 22, the dryer supports a wide range of capacities from 100 to 6,000 liters. It operates at design temperatures from -10 to 150°C and pressures from full vacuum to +6 barg. Optional accessories, including dust filters with automatic back cleaning, CIP systems, and vacuum systems, further optimize its performance.

Vacuum pan dryer for heat-sensitive pasty products

In the pharmaceutical industry, producing free-flowing, sterile bulk pharmaceuticals requires advanced drying technologies. Traditional tray freeze dryers often demand significant manual handling and post-processing, posing challenges in efficiency and product quality.
<h2>Produce sterile bulk powder efficiently</h2>
The Active Freeze Dryer (AFD) from Hosokawa Micron is designed to produce consistent, high-quality free-flowing powders in a single, contamination-free process. This system agitates the material in a specially designed chamber, freezing it to form free-flowing granules regardless of whether the starting material is a liquid, paste, or granular solid. The subsequent vacuum drying process sublimes the frozen water, transforming the granules into fine, dry particles. Heat applied to the vessel jacket ensures an even distribution of temperature throughout the material. With excellent cleanability and minimal labor requirements, the AFD system is suitable for producing antibiotics, APIs, collagens, and proteins. The system is available in three models, catering to different volumes and sublimation capacities.

Pharmaceutical freeze dryer

Managing the stability and longevity of temperature-sensitive pharmaceutical products requires advanced preservation techniques. Freeze-drying is critical in this context, as it removes solvents while maintaining the molecular structure of active ingredients.
<h2>Efficiently preserving pharmaceutical products</h2>
The LYOMAX by IMA is an industrial freeze dryer designed to meet the stringent requirements of the pharmaceutical industry. This freeze dryer offers customizable configurations and sizes ranging from 1 m² to 100 m², accommodating a wide variety of production needs. With shelf cooling capabilities from -55°C to +70°C and condenser cooling between -75°C and +120°C, LYOMAX ensures precise temperature control. It includes patented FUSION™ shelves that reduce energy consumption and enhance heat transfer. Furthermore, the integrated automatic, semi-automatic, and manual loading/unloading systems streamline the process, reducing downtime. Designed to comply with GAMP, cGMP, and FDA guidelines, LYOMAX is equipped with VERISEQ® technology for controlled nucleation and KryoAir, an eco-friendly refrigeration system.

Industrial GMP freeze dryer

When working with small production batches in pharmaceutical processes, maintaining product quality and batch uniformity is crucial. Traditional drying methods may not suffice for such stringent requirements, making precise freeze drying techniques essential.
<h2>Ensures consistent drying with advanced technology</h2>
The MINIMAX by IMA is a GMP-compliant, small-scale freeze dryer designed to meet the specific demands of handling small production batches. Based on the successful LYOMAX concept, MINIMAX provides scalable lyophilization technologies from formulation to full commercial production. With several configurations available, it offers shelf areas ranging from 1.0 up to 3.9 m², and ice condenser capacities from 29 to 78 kg, with minimum condenser temperatures of –75°C. It is equipped with Process Analytical Technologies (PAT) to optimize drying outcomes and gives a data-rich environment for monitoring. It supports non-aqueous solvents and high-potent products processing and can integrate with isolation technology and automatic vial-loading systems. The patented FUSION™ shelf technology ensures higher-quality heat transfer, enhancing process reliability. Designed with redundancy and configurable options, the MINIMAX provides a reliable and versatile drying solution.

Small-scale freeze dryer for pharmaceutical applications

In pharmaceutical manufacturing, ensuring uniform and high-quality coating of tablets is crucial. This process can face challenges such as inconsistent coating, high energy consumption, and operator exposure to potent Active Pharmaceutical Ingredients (APIs).
<h2>Uniformly coat tablets while reducing operator exposure</h2>
The PERFIMA by IMA is a perforated coating system designed for film and sugar coating. Its pan shape and central drum baffles ensure perfect mixing of cores, allowing batch sizes from 25% to 100% of the pan capacity. The system includes automatic loading and unloading, energy-efficient air ducts, and a Clean-In-Place system validated by the University of Parma. The PERFIMA is also suitable for containment installations, reducing operator exposure to hazardous APIs. Energy efficiency is further enhanced by an AHU that recovers treated air, maintaining optimal performance. The system supports diverse applications, from standard to dynamic tablet processing.

Industrial tablet coating solution

In pharmaceutical production, the need for efficient and contained granulation processes is critical. Traditional multi-step methods can expose operators to hazardous materials and increase contamination risks, resulting in compromised product quality and longer processing times.
<h2>Achieve seamless in-containment granulation</h2>
The ROTO CUBE from IMA is a single-pot processor that revolutionizes granulation by integrating multiple processing steps within a sealed bowl. This system handles everything from the loading of raw powders to the discharge of dry milled granules without the need for product transfers. Featuring accurate detection of the wet granulation end-point and a tilting bowl design for optimal heat exchange, the ROTO CUBE improves drying efficiency and prevents product sticking. The GA.ST. system enhances vacuum drying through inert gas injection, ensuring a dust-free process and safe solvent use. Suitable for high-potency active ingredients (HAPI), the ROTO CUBE maximizes product yield and simplifies cleaning operations.

Single-pot granulation processor for pharmaceutical applications

When taking a tablet, it is usually the job of our stomach to break down the medication to make it ready to be absorbed into the bloodstream. However, some drugs are not meant to be dissolved in the stomach because the acidic pH of the stomach can disintegrate the drug, making it no longer effective. Using tablet coating equipment that applies a polymer barrier to the tablet makes it possible to protect it from stomach acidity.

Enteric Coated Tablets

Microtablets range between 1 and 4 millimeters, making the dosage form an excellent delivery system in polypharmacy. The size of the products makes them easier pills to swallow, but microtablets production brings a unique set of complexities.

Microtablets

L.B. Bohle is a technology leader in machines, systems and processes for the pharmaceutical, chemical, food and nutraceutical industries. Our focus is on equipment for tablet manufacturing.

Continuous wet granulation and drying have been widely discussed in pharmaceutical research and development (R&amp;D) and industry. Daniel Emanuele from the Dortmund University of Applied Sciences and Robin Meier from L.B. Bohle set out to test if the QbCon® 1 from L.B. Bohle is suitable for extended process times and meets the quality standards of the market.


<h2>The research zoomed into three metrics</h2>
The research focused on measuring moisture content, residence time distribution, and granule size distribution of the granulator and dryer. The results indicate that the dryer achieves very precise and consistent residence time distributions, resulting in uniform drying of granules across different size categories. The process consistently produces granules with the desired moisture content and particle size over extended periods. By adjusting the conveying speed of the granules in the dryer while keeping other parameters constant, the researchers were able to determine the limits for specific process/formulation combinations, primarily influenced by the depth of the fluid bed.

The ability to monitor the process in real time makes the QbCon® 1 an ideal choice for introducing continuous wet granulation, especially with its innovative drying process.

See it in the video!

[embed]https://youtu.be/XRyCPRNM9jE[/embed]

&nbsp;

Scientifically tested continuous drying for your tablets

Pharmaceutical

Pharmaceutical powders provide longer shelf life and better stability than liquid dosage forms. But the processing of pharmaceutical powders is crucial for growing segments besides pharmacy. Functional foods and cosmetics formulated with active ingredients and excipients depend on powdered forms to fulfill their promises.

Pharmaceutical powder

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

Among all dosage forms in use today, tablets constitute the most common one. They are pharmaceutical solid dosage forms containing active ingredients and excipients such as diluents, binders, glidants, and lubricants. Using tablet making equipment, these solid dosage forms are made by compression of granules or powder blends and then shaped by molding.

Tablets

In pharmaceutical industries, where large-volume production is the norm, compactors or granulators are used to turn powdered materials into granules. As hydraulic systems are commonly utilized in these granulators, the compressibility is affected by the properties of the oil used. Certain oils can be compressed more than others and their properties degrade over time and are affected by temperature fluctuations.


<h2>Compacting dry powder into granules using an electromechanical roller drive</h2>
The Dry Granulator BRC 100 from L.B. Bohle, is a compacting system that turns powdered materials into granules for pharmaceutical industry applications. The system utilizes an electromechanical roller drive to provide precise control, consistent compressibility, and minimal material loss compared to hydraulic systems that rely on oil properties to drive the rollers.

This setup offers less maintenance as it does not require oil changes and an oil cooling system. The system has a flexible sieve setup allowing for the use of either a conical sieve or an oscillating sieve to obtain the desired granule size of the product coming out from the rollers. The granulator comes standard with integrated WIP (Washing in Place) nozzles for effective and easy cleaning. The entire system can be assembled or disassembled quickly, which helps improve maintenance and installation.

&nbsp;

Dry granulator for pharmaceutical powders

Chewable tablets are suitable for patients who have difficulty swallowing. Chewable tablet formulation masks the natural flavors of pharma drugs and alters their aftertaste. But besides the taste, chewable tablets favor the bioavailability of pharmaceutical ingredients.

Chewable tablets

Pharmaceutical innovations, particularly with highly potent active ingredients (HPAIs), are thriving largely in oncology medication. However, ensuring safety for both operators and patients is paramount. L.B. Bohle has sought to make sure that your medicine comes with the highest quality and that your operators stay safe during the dry granulation process.


<h2>Safe production = safe medicine</h2>
If we look at pharmaceutical production at containment level OEB 5, which has high potency and toxicity, you must make sure that there is absolutely no direct contact between your operators and the medical substances.  L.B. Bohle has tackled the concerns and can integrate them within their BRC dry granulators. Features such as glove boxes for safe handling and an integrated isolator unit in the compacting unit comply with manufacturing guidelines while prioritizing safety and efficiency.

The granulators have a containment port underneath the sieve unit for the removal of granules and a containment port for flake sample collection. You can also remove the product from inside the granulator residue-free with integrated WIP equipment.

Are you eager to learn more? <a href="https://lbbohle.com/pharma-whitepaper-pharma-product-brochures">Bring yourself up to speed with the whitepapers from L.B. Bohle.</a>

Aim your safety standards high, while granulating dry

Manufacturing pharmaceutical solids like tablets requires using a proper blender to blend dry powders into a homogenous mixture. Having a blender that can accommodate various blending container sizes allows easy adjustment of the production volume.


<h3>Blending homogenously dry powder batches using a stationary blending device</h3>
The Container Blenders PM from Bohle is a blending system for fine solids and powders in pharmaceutical applications. The system features a wide variety of blending containers with various capacities that can handle square or round containers. Each blending container can be used to mix powders effectively at a range between 20% to 85% of its total container volume for densities ranging from 0.2 to 1.2 kg/L. The blending process is done in a closed system; each container has an inner lid for filling.

The blending system rotates at 6 rpm with an option to increase the speed depending on process requirements. It can be equipped with a chopper that operates at a speed of approximately 750 rpm to break solid lumps and chop small amounts of ingredients.

Product changeover can be done quickly by simply exchanging the blending container. The entire system can also be used as a milling station for bin-to-bin product transfer.

Container blender for pharmaceuticals

Multilayer tablets are a popular fixed-dose combination (FDC) offering a range of release profiles for effective drug delivery. Multilayer tablet technology solves challenges to API consistency, allowing manufacturers to develop formulations from incompatible ingredients while optimizing the release profile for immediate release and controlled release.

Multi-layer tablets

Whether you are making pharmaceuticals, chemicals, or nutraceuticals, you will need to blend your ingredients. Depending on your product and production needs, finding a suitable blender is the utmost priority, but it can prove to be a challenge. L.B. Bohle has tackled the need and come out with a wide array of blenders, adjustable for your processing needs and goals.


<h2>Five solutions to fit your needs</h2>
Their portfolio of blenders can be scaled up to 12,000 liters with standard exchangeable containers up to 2,400 liters. You can choose from five different pick-up systems.

First, you can request standard load arm and clamps, with containers docked using electronically monitored quick clamps for your blender. In this solution containers up to 1,200 liters, mounted on an undercarriage, can be adapted without additional lifting equipment. Additionally, you can opt for a chopper installation whose drive is integrated into the load arm.

Secondly, you can request a blender version where the system can be swiveled around its vertical axis. This design comes with a huge advantage: long service life and extremely low maintenance requirements!

Did this spark your interest and are you curious to find out about the other systems? <a href="https://lbbohle.com/pharma-whitepaper-pharma-product-brochures">Read more on the whitepapers from the L.B. Bohle team.</a>

Discover the best mix for your blending application

Chemical

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

Producing the finest micro-emulsions and suspensions requires a mixing machine that generates extremely high shear.  Multi-staged rotor/stator dispersing machines work well for this purpose because of the high shear forces applied to the mixture at each rotor/stator stage.  A rotor /stator dispersing machine that also incorporates extremely fast rotation and resultant tip speeds for even greater shearing action will lead to the creation of super-fine emulsions and ensure the success of your process.
<h2>Top-of-the-line rotor/stator dispersion with utlra high shear for nano-scale particle emulsions and suspensions</h2>
The DISPAX-REACTOR® DRS from IKA is an inline ultra high shear dispersing machine used to achieve the finest micro-emulsions and suspensions. Extremely high shear rates (up to 190.000 1/s) combined with a fine generator geometry enable crushing of droplets and solids particles down to the nanoscale. The resulting product has long-term stability which reduces the need for emulsifying agents and thickeners. Because of the extremely high energy density, other dispersing aids can be reduced or possibly eliminated.

The DRS is usually equipped with a two-stage rotor-stator system (generators). The high tip speed of 40 m/s (10.000 fpm) often negates the need for a third stage. The ultra-fine dispersing machine, designed with the same high quality features as the ULTRA-TURRAX® UTL and the DISPAX-REACTOR® DR, is especially well suited for challenging pharmaceutical applications.  The units are designed for easy and reliable scalability and sizes are available with flow rates from 70 to 40.000 liters per hour.

Ultra-fine dispersing machine for emulsions and suspensions

Used in the pharmaceutical industry to produce tablets and capsules, among others, pharmaceutical granules are made to enhance the uniformity and flow of powder, increase the density of the blend and reduce dust and, therefore, toxic exposure. The choice of the granulation process, whether it is wet, dry, or direct compression, as well as the selection of appropriate pharmaceutical granulation equipment, depends on the specific drug being formulated.

Pharmaceutical granules

Built upon its world-leading laboratory equipment, IKA Process is a game changing manufacturer of dispersing machines, homogenizers, stirrers, jet flow agitators, and kneading machines.

In the pharmaceutical industry, change often moves at a snail’s pace due to stringent regulations, but it does happen.



Traditionally, API manufacturers relied on the dry milling process, which begins with crystallization or precipitation within a liquid medium, where crystals form and grow. These crystals are separated using a centrifuge, dried, and finally subjected to dry milling before tableting.

As APIs became more potent, dry handling became problematic due to dust generation, causing cleaning issues and product loss. Furthermore, stricter ATEX regulations for handling hazardous powders have expedited the demand for change.

It’s not as simple as just mixing dry ingredients together, and voila, you have your API. APIs are always, and I mean always, synthesized within a liquid medium to form solid crystals. If liquid is always a part of the equation, why not control the growth of those crystals already in the crystallization step?

And this is where wet milling came into play. This approach allows early particle size control during precipitation, enhancing pharmaceutical manufacturers’ control over the API’s final particle size and distribution.
<h2>“<em>The value of an idea lies in the using of it</em>.” – The benefit of early particle size reduction</h2>
We had a chance to speak with Werner Kanzinger, <a href="https://www.ikaprocess.com/en/Products/Process-plants-cph-18/?gclid=Cj0KCQjwmICoBhDxARIsABXkXlLSTjoDkEyEOxqysB6am7wNW99asG4jDKpXJpsQO5pzSj_wv8ZdyHYaAlsvEALw_wcB">IKA</a> Vice President, one of the first to use wet milling for API production. Creating new pharmaceuticals requires starting from scratch and developing principles in the R&amp;D world. To address this need, IKA introduced an innovative three-stage inline dispersing technology called the <a href="https://www.ikaprocess.com/en/Products/Pilot-plants-cph-40/magic-LAB-csb-MLAB/">Magic Lab</a>.

“<em>We knocked on every door in the R&amp;D world and were surprised how the technology was well-received. The industry recognized its</em><em> potential to simplify production through early-stage particle size reduction,” </em>Werner explains.

According to Werner: “<em>Even at a half-liter batch, APIs are very valuable and pricey. As production scales up to 1000 liters per batch, the cost can be over 1 million, and nobody wants to take any risk.”</em>

To serve the industry across diverse production scales, IKA replicated Magic Lab’s success on a larger scale, ensuring consistent milling outcomes without compromising quality.
<h2>No dust, no fuss - Wet milling is here to simplify your life by shortening your production time</h2>
In dry milling, solid materials undergo high-speed impact and shearing forces, generating airborne dust particles. This dust settles on equipment, necessitating extensive cleaning to prevent cross-contamination.

“A w<em>et mill is already designed to create a high-turbulence environment, which helps with dust reduction</em>,” Werner continues.

Additionally, wet mills are easier to clean than dry mills due to their smaller and less complex internals, requiring less time and effort. Operating already during the crystallization step, wet milling allows for localized energy application. This reduces energy consumption compared to drum mills.

“<em>IKA three-stage inline technology allows for complete drainage after use. The product flows from the top to the bottom through a three-stage rotor-stator, progressively reducing particle size from coarse to fine. Since it’s vertically installed, no product remains inside, making cleaning straightforward,</em>” Werner concludes.

Just remember, it is better to move forward at a snail’s pace than backward at any pace.

Wet milling: The revolution in the API production

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.

Biopharmaceuticals

The most important part of a capsule is its contents. But if the shell is not carefully made, the dosage ingredients inside lose effectiveness. From molding to sizing, capsule manufacturing equipment forms perfectly-matching husks ready for filling. The simplicity of encapsulation revolutionized pharmaceuticals since it was introduced in the 19<sup>th</sup> century. However, capsules are changing to increase delivery efficiency and reduce the dependency on gelatin.

Capsules

<p class="filterable-grid__description">Liquid dosage forms are designed for easy absorption. The body quickly carries the active ingredients through the system and triggers the required response. But the greatest advantage of this medicinal type is its flexibility in formulation and dispensation. From lotions and syrups to drops and sprays, liquid solutions can be adapted to different administration routes including parenteral, topical, and oral. The fundamental liquid dosage manufacturing process involves dissolving or suspending solutes in a fluid. But that is not enough. A precise blend of excipients is needed to make the medicine go down.</p>

Liquid dosage forms

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Powder containment is the cornerstone of chemical and pharmaceutical manufacturing. Floating particles do not only represent efficiency loss but serious hazards too. Lack of tightness during the powder discharge process leads to cross-contamination and operational health risks.


<h3>Dock transfer systems squarely in place</h3>
The ASBV active/passive valve interface by Andocksysteme locks into position, minimizing exposure of material during powder discharge. The system has two split valves – one active, one passive – that can be easily and reliably centred on each other at a tolerance of ± 14 mm.

Once the units are docked, the valve discs open simultaneously, preventing exposure of the products during transfers. The dust-tight environment achieves contamination values lower than 1µg/m3.

The ASBV solution is fitted with EPDM seals and are optional with a wide range of materials, such as PTFE, offering top-range chemical resistance. All seals are made from FDA-approved materials and can handle a wide range of temperatures as well as explosion-proof executions.

Washing the ASBV interface is simple as the system can be connected to a WIP loop to flush out residual powders. These containment solutions serve applications with an exceptional performance and are easy to be integrated. Moreover, high quality parts and reduced complexity drives simple maintenance.

High containment split butterfly valve

Andocksysteme is a specialist in developing and engineering high-quality containment docking and solutions for bulk material.

The rise of high-potency ingredients (HPAPI) is taking medication into unchartered territory. Since the turn of the century, the pharmaceutical industry has developed a wave of targeted therapeutics formulated with more potent drugs in smaller doses.

Besides producing a more effective action against their biomedical targets, these innovative medicines are also lighter on excipients and provoke fewer side effects for patients. However, they do cause considerable side effects for manufacturers.


<h3>Higher potency can be too much of a good thing</h3>
HPAPI materials pose a risk of toxic exposure to operators. Process technology is designed to meet EHS guidelines, protecting handlers from hazardous substances. At the same time, it must also adhere to GMP standards to prevent contamination. However, the real danger lies at the inlets and outlets of the machines, as <a href="https://andocksysteme.de/en/" target="_blank" rel="noopener">Andocksysteme</a> Product Manager Duncan Ehrmann points out.

“It is all well and good when a mixer is blending chemicals, or a dryer is reducing moisture,” says Duncan. “But things get tricky while the materials are transferred from the mixer to the dryer.”

There is no such thing as a fully closed system; discharge will always release particles into the air. So, the challenge is to minimize that amount to the greatest extent possible.

The industry answer is the split butterfly valve principle, joining the ‘mouths’ of two systems and opening them synchronously. But engineering the concept into an actual pharma-grade interface is another story.
<h3>Big on seals, small on parts</h3>
Andocksysteme developed a valve solution that achieves contamination values lower than 1μg/m3. A primary contributor to this degree of containment is the minimalist construction of the interface. Designed with the bare minimum of separate parts, the valves significantly restrict roaming space for flowing powders.

"We designed  our technology with large seals  to cover the openings," explains Duncan, "A bigger seal exerts higher pressure, locking the active/passive valves tighter together.”

The state-of-the-art system meets the OEB 5 levels of protection required when handling ingredients with high pharmacological and toxic effects.

HPAPI particles move around a lot during processing. Their manufacturing cycles are long and winding, but high-containment valves hold them safely within that loop.

Closing the containment loop in HPAPI manufacturing

Italvacuum is specialised in vacuum drying technologies for the processing of wet feed materials to produce active pharmaceutical ingredients (API) or fine chemicals.

Without friction, we would not be able to walk, jot down notes, or slice a pie. Friction resists the relative motion of two objects that come in contact, generating grip between their surfaces.

But if you’re drying high-potency API, friction is the last thing you need. The force exerts mechanical and thermal stress on the ingredients that could destabilize the materials and compromise the quality of your end product.
<h3>A poor work of friction</h3>
High-potency <a href="https://making.com/active-pharmaceutical-ingredients-api">active pharmaceutical ingredients (API)</a> require thorough drying to ensure homogeneity in the production process. Once crystallized and isolated from organic solvents, the ingredients must be prepared into free-flowing materials ready for precision dosing, formulating, and formatting.

The drying step is a delicate process that converts the particles into workable materials without altering the chemical profiles developed during filtration. Vacuum drying is a cornerstone of this production stage. The method removes a high rate of bound moisture from materials at relatively low temperatures.

But the vacuum method solves one challenge and creates another. The agitator inside the drum spreads the ingredients over a broader area to expose trapped moisture to vaporization. Therefore, the blades on the agitator make direct contact with the surface of the HPAPI particles. This process creates friction at a millimetric level, producing heat.
<h3>It's a dryer, not a heater</h3>
Dario Penco, a technical engineer at <a href="https://www.italvacuum.com/en/" target="_blank" rel="noopener">Italvacuum</a>, says that adding thermal energy during the drying stage overheats the blend: “Subjecting sensitive materials to friction during the drying stage adds unnecessary heating and risks degrading the ingredients.”

The emergence of high-potency drugs has made this challenge even more pressing. The slightest distortions in the composition of the particles create a ripple effect across the manufacturing line.

Production engineering is developing new ways to overcome this hurdle and minimize friction occurring in a vacuum dryer. Novel design approaches to the blade profile reduce the physical contact with the materials and limit thermal stress significantly. Keeping temperatures at a constant ensures higher-quality pharmaceutical ingredients. And just like well-baked pizza, everyone wants a slice of that.

Lowering heat stresses on API by reducing friction

Find production technology for Drying API, and connect directly with leading machine manufacturers worldwide

Drying API

Drying API - Making.com

https://making-tst.imgix.net/2021/06/Active-pharmaceutical-ingredients-making-equipment-1-scaled.jpg

Home

The marketplace for finding innovative production technology

Making.com

https://making-tst.imgix.net/2022/12/makingCopy.png