Fluid bed processing of pharmaceuticals

Enhance your pharmaceutical production with versatile fluid bed processors, enabling precise blending, granulating, drying, and coating to support complex formulations and meet stringent quality standards.

Processes and Coats Pharmaceutical Powders and Granules

The FlexStream Fluid Bed Processor from GEA combines granulation, drying, and coating in a single, versatile system designed specifically for pharmaceutical applications. Known for its precision and efficiency, it performs multi-step processing from a single unit, enhancing production flexibility and reducing equipment footprint. This processor is particularly suited for creating effervescent tablets, vitamin granules, and enteric-coated pellets. It operates in batch, continuous, pilot, and industrial-size modes, accommodating a range of production scales. The FlexStream integrates easily into existing systems, featuring PLC control with options for automated FDA-compliant monitoring. The unique nozzle design eliminates over-wetting without needing compressed air, boosting yield and lowering energy use. Available in various material options, it meets cGMP conditions while offering easy cleaning and maintenance solutions, including CIP. Its modular construction allows customization, ensuring it fits specific needs for pharmaceutical manufacturers, R&D departments, and CMOs.

Benefits

  • Enhances production flexibility by integrating multiple processes in one unit.
  • Minimizes operational costs with efficient energy use and reduced need for compressed air.
  • Achieves consistent product quality with in-line particle growth measurement and PAT compliance.
  • Streamlines cleaning and maintenance with integrated CIP system.
  • Ensures compliance with cGMP and FDA standards for pharmaceutical manufacturing.

General


Applications
Pharmaceutical tablets,Nutraceuticals,Pharmaceutical powder,Coating materials,Pharmaceuticals
End products
Ibuprofen tablets,Gelatin capsules,Vitamin c granules,Enteric-coated pellets,Herbal extract capsules,Coated aspirin tablets,Multivitamin powder blend,Effervescent tablets,Nutritional supplement tablets,Anti-caking powder for tablets
Steps before
Mixing,Blending,Purification
Steps after
Coating,Tablet Pressing,Packing
Input ingredients
pharmaceutical compounds,liquid droplets,suspensions,solutions,inert core,active material
Output ingredients
blended materials,granules,pellets,coated particles,free-flowing granulates,dry granules
Market info
GEA is known for its expertise in engineering innovative and sustainable equipment and solutions, focusing on sectors such as food, beverages, pharmaceuticals, and energy, with a reputation for quality, efficiency, and advanced technological applications in industrial processing.

Technical Specifications


Air Speed
1–20 m/s
Automation
PLC-controlled
Batch size
25-1800 L
Capacity
Small to industrial-size
Cycle Time
Very short processing times
Drying Time
Rapid
Granulation process
High velocity air stream
Humidity
Low in holding area
Inlet Air Preparation
Filter and conditioning units
Process Control
FDA-compliant
Product container
Single for all operations
Spray Nozzle Position
Side walls
Temperature control
Granulation and drying
Type
Fluid Bed Processor

Operating Characteristics


Working Mechanism
Fluid bed technology
Integrated Steps
Granulation,drying,pellet coating
Batch vs. Continuous Operation
Batch production
Automation Level
PLC / SCADA
CIP/SIP
CIP 121°C / SIP 135°C
Energy Efficiency
High,comparative
Process Monitoring
Online (PAT) analyzers
Changeover Time
Reduced downtime
Containment Level
High containment,GMP compliant

Material Compatibility


Density/particle size
0.5–2.5 g/cm³ / 50–1000 µm

Product type Characteristics


Granulation type
Fluid Bed Granulation
Coating method
Top Spray / Precision Coating
Pelletizing method
Precision Layering
Drying method
Fluid Bed Drying
Batch production conditions
cGMP
Blending method
Fluid Bed Blending
Containment level
High Containment
Process flexibility
Single Unit Operations
Formulation stage
Clinical Development and Full-Scale Manufacture
Spraying system
Spray Dryer Granulator


GMP Compliance
Yes
FDA Compliance
Yes
FDA Materials
Yes
CGMP Conditions
Yes
CE marking
Yes

Physical Characteristics


Machine footprint
Compact
Configuration
Modular
Height
Reduced
Width
Reduced
Design
Single product container
Process integration
Granulation,drying,coating in one
Nozzle Position
Side wall mounted
Air flow design
Pneumatic particle control

Custom Options


Control panel type
PLC and PC-based
Process monitoring integration
Online PAT analyzers
Dryer configuration
Standardized modular design
Spray nozzle position
Mounted in side walls
Inlet air preparation unit
Multiple filter options
Spraying systems
Nozzles and pumps per process needs
Product discharge method
Pneumatic or gravity-based
Containment techniques
Buck® MC Valve and Hicoflex® interfaces