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Maker - Product Challenge

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Compression Technologies

Industrial

In high-demand scenarios like hydrogen refueling or storage stations, there's a need for a reliable compression solution that ensures safety and efficiency. Traditional methods often struggle with maintaining high pressure levels and purity without frequent maintenance.
<h2>Generate high purity hydrogen up to 950 bar</h2>
The Hiperbaric 1KS 95 Compressor Group is a compact, modular solution for hydrogen compression. It produces inlet pressures of 20-200 bar and can deliver hydrogen at pressures up to 950 bar. Featuring a two-stage intensifier cylinder, it provides high hydraulic and cooling efficiency. The system includes a hydraulic system, refrigeration system, vent circuit, instrumentation, and a control panel. Designed for scalability, it meets varying production demands and maintains hydrogen purity with its oil-free design. Developed by Hiperbaric, this unit adheres to international safety standards, making it suitable for installation worldwide.

Hydrogen compression solution for refueling stations

Compression

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

Industrial filtration equipment separates solid matter from liquid by using a filter medium. The filter allows only the fluid to pass through but retains the solid matter. The choice of filtration equipment depends on the particle size, the consistency of the mixture, and the nature of your product.

Filtration

Hydrogen refueling stations and storage facilities face challenges in efficiently compressing hydrogen to high pressures while ensuring safety and reliability. These facilities seek systems that can handle varying production demands and maintain hydrogen purity.
<h2>Compact and safe hydrogen compression up to 500 bar</h2>
The Hiperbaric 1KS 50 is designed specifically for hydrogen compression, offering a modular and scalable solution. It includes a two-stage intensifier cylinder, hydraulic system, refrigeration system, vent circuit, and control panel to ensure safe and reliable operation. With hydrogen inlet pressures between 20-40 bar and outlet pressures up to 500 bar, this system provides high purification thanks to its ‘oil-free’ design and innovative cooling for greater efficiency. The plug-and-play design is suitable for hydrogen refueling or storage stations and complies with stringent international standards like DIRECTIVE 1999/92/EC and DIRECTIVE 2014/34/EU.

Hydrogen compression solution for refueling and storage stations

Continuous

In pharmaceutical manufacturing, achieving efficient direct compression of tablets often involves overcoming challenges related to throughput, process control, and space constraints.
<h2>Continuous dosing, blending, and compression in one system</h2>
The FE CPS from Fette Compacting is a comprehensive continuous processing system designed to streamline tablet production. Featuring a compact footprint of 5 x 6.5 meters, it integrates dosing, blending, and conveying processes seamlessly with a FE55 tablet press. The system is equipped with an advanced Human Machine Interface (HMI) for centralized control, simplifying the monitoring and adjustment of production parameters. The embedded Process Analytical Technology (ePAT) ensures real-time quality control by continuously analyzing critical production metrics. The dust-tight design and easy-to-clean process units enhance operator safety and reduce maintenance time, making it ideal for environments requiring quick product changeovers. With throughput capacities ranging from 5 to 200 kg/h, the FE CPS offers high flexibility for a wide range of pharmaceutical formulations.

Continuous direct compression system for tablet production

Blending

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

solid

In laboratories and industries where precise sample preparation for plastic testing is a regular requirement, ensuring compliance with rigorous ASTM standards can be challenging. Accurate compression molding of test plaque or bar specimens is crucial for achieving reliable results.
<h2>Prepare plastic samples for Astm testing</h2>
The Hydraulic Compression Plastic/ASTM Press by Carver (ACS Group) is specially configured for the compression molding of test plaque, bar specimens, polyethylene, and other thermoplastic resins. The press adheres to ASTM Method D 4703, Procedure C, ensuring compliance with industry standards. It is equipped with heating and cooling platens and features a programmable digital controller with heating/cooling loops for each platen. Additionally, the built-in program maintains a consistent 15°/minute +/-2°C cooling rate. This equipment is ideal for laboratories and industries focused on precise and consistent plastic sample preparation.

Hydraulic compression press for Astm plastic sample preparation

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

Molding

In large-scale pharmaceutical manufacturing, ensuring the consistent quality and precise weight of tablets across extensive production runs is a common challenge. This necessitates the use of advanced technology to maintain high standards while optimizing efficiency and minimizing downtime.
<h2>Enables high-speed, consistent tablet production</h2>
The PROTAB™ 700 from ACG World is a double rotary press designed for high-volume tablet compression. It offers functionalities for producing both monolayer and bilayer tablets. The machine stands out due to its interchangeable turret design, which allows for the compression of various tablet sizes at different speeds. Its servo-based automatic weight control ensures high-quality tablets of consistently precise weight. The sophisticated feeder design minimizes waste by achieving 100 grams per feeder of leftover powder. The PROTAB™ 700 also features the InstAmend technology, which detects and rectifies faulty punches immediately, reducing downtime and preventing long process interruptions. Additionally, the tool-less design of assemblies facilitates faster, simplified batch-to-batch changeovers, enhancing productivity.

Double rotary press for high-volume tablet compression

Batch

Pilot

When working with highly potent active ingredients (HAPI), maintaining safety and containment is critical. A solution is needed to handle R&D applications and pilot batches while protecting both operators and the environment from exposure to hazardous substances.
<h2>Ensure operator safety and environmental protection</h2>
The PREXIMA THC by IMA is a tablet press designed for total high containment, suitable for R&D applications, pilot batches, and production support. The PREXIMA THC features sealed doors, limited contact surfaces, and negative pressure inside the processing area, ensuring safety and containment. It includes a turret of 8 stations (4B + 4D) and provides pre-compression and main compression forces similar to production machines, offering scalability. Operator access to the internal parts is facilitated via glove ports, enhancing safety. The machine configuration is flexible and allows for easy integration with existing solid dose processing lines. Equipped with IMA’s MAX HMI, it offers improved operator efficiency, prompt responsiveness, and easy learning.

Tablet press for high containment environments

Compaction machines and technologies crush or compress materials and make them denser. Compaction can be used to simply save space or to shape materials into a desired form or format. Tablets, pellets, or briquets are formed by compactors but powder presses also help form cosmetic eyeshadow or face powder.

Compaction

In pharmaceutical and biotechnological industries, freeze drying is a critical process for preserving sensitive materials. Traditional refrigeration systems often involve toxic and environmentally harmful refrigerants, creating challenges in sustainability and safety.
<h2>Eco-friendly air-based refrigeration for ultra-low temperatures</h2>
The KryoAir from IMA is an innovative refrigeration system that uses air as a refrigerant in freeze dryers. This technology is based on a series of compression, cooling, and expansion steps of air, which can be cooled to temperatures as low as -100°C. Comprised of an expander integrated with a compressor, a primary cooler for heat dissipation, and a heat-recovery heat exchanger, the KryoAir system ensures efficient refrigeration with minimal environmental impact. It combines a novel thermal energy storage system to handle peak heat demands, which is compact and has no moving parts. This system is compliant with environmental regulations and avoids the ozone depletion and global warming impacts associated with conventional refrigerants.

Refrigeration system for freeze drying

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

Lyophilization

In pharmaceutical operations, especially during compression and encapsulation, substantial amounts of waste powder are generated. Efficiently recovering this waste is crucial to prevent material loss, maintain cleaner workplaces, and ensure compliance with regulatory standards.
<h2>Recover up to 99.9% of waste powder</h2>
The Hanningfield Uni-Dust cyclone is a high-efficiency system designed to recover waste powder from pharmaceutical oral solid dosage (OSD) processes such as compression and encapsulation. This equipment enables the capture of waste powder with an impressive efficiency rate of 90 - 99.9%, minimizing material loss and allowing for potential reintroduction into the process. It operates without filters, significantly reducing maintenance needs. Built from GMP-compatible stainless steel, it ensures compliance with regulatory standards. The Uni-Dust cyclone can connect to various process machinery via flexible hoses or stainless steel pipework, and is capable of integrating with ancillary systems like tablet dedusters or capsule polishers. Available in various models with different airflow capacities, it suits multiple industrial requirements.

Waste powder recovery cyclone for pharmaceutical processes

In the pharmaceutical world, encapsulation refers to various techniques to enclose and protect the drug ingredients by forming the capsule shell. Encapsulation equipment changes depending on whether the manufacturer needs to produce a soft or hard gel capsule. For instance, encapsulation systems and machines for softgels control the entire process from start to finish because their shells are filled at the same time they are produced. On the other hand, the filling of hard gel capsules comes by separating the body from the cap, and after the filling operations, the two parts are sealed together again, forming the shell.

Encapsulation

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

Recovery

Powder

In petrochemical plants, refineries, and gas treatment facilities, reliable and efficient compression of process gases is crucial. Traditional compressors often face challenges such as high energy consumption, pulsation, and oil contamination, leading to costly downtime and maintenance.
<h2>Ensure efficient, pulsation-free gas compression</h2>
The BORSIG ZM centrifugal compressor series offers multistage integrally geared centrifugal compressors with up to 8 stages. These compressors are driven by steam turbines, gas turbines, or electric motors, and comply with API 617 (chapter 3) and 672 (4th edition) standards. High-efficiency operation is achieved through speed variation, cooling between each stage, inlet guide vane control, and axial flow into blades. These features address the common issues faced by reciprocating compressors, providing pulsation-free compression and oil-free fluid handling. Ideal for industries such as petrochemical, refineries, gas treatment, fertilizer production, power plants, and steel manufacturing, they deliver consistent performance with minimal maintenance. Discharge pressures can reach up to 200 bara, capacities up to 300,000 m³/h, and power up to 25,000 kW, making them versatile for various industrial applications.

Integrally geared centrifugal compressors for process gases

In many industrial processes, valuable gases like propylene and nitrogen are lost as waste. This leads to both economic and environmental inefficiencies. Efficient recovery of these gases can minimize waste and maximize resource utilization.
<h2>Recover and purify valuable gases</h2>
The BORSIG Propylene and Nitrogen Recovery Unit employs a combination of compression, condensation, and membrane separation to recover high-purity propylene and nitrogen from purge gas streams. This system features a straightforward integration into existing and new installations. The initial stage compresses and condenses the purge gas, segregating the condensate. The gas is then fed into a hydrocarbon-selective membrane system, separating propylene and nitrogen streams effectively. The propylene can be recovered in liquid or gaseous form, while the nitrogen achieves over 99 mol% purity. BORSIG’s proprietary membrane technology ensures high recovery rates and operational efficiency.

Propylene and nitrogen recovery system for industrial applications

Condensation

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

In industrial polymer production, the recovery of valuable monomers from process streams is critical to minimize waste and optimize resource utilization. Effective separation of hydrocarbons from nitrogen is essential to achieve high recovery rates and product purity.
<h2>Recover valuable monomers with high purity</h2>
The BORSIG Monomer Recovery Unit features a flexible system that can handle multiple components, depending on the upstream process. The unit combines membrane separation with operations such as compression, condensation, and heating to efficiently separate hydrocarbons from nitrogen. The hydrocarbon-enriched permeate stream is routed to the process or the suction side of a compressor to enhance condensation. For applications requiring highly purified nitrogen, an additional membrane stage can be incorporated. Operating at moderate pressures and temperatures ensures safe and reliable performance with low maintenance. The modular design allows for quick installation and easy implementation, adaptable to both new and existing plants.

Monomer recovery unit

liquid

In pharmaceutical and nutraceutical industries, producing tablets in small and medium batches can present challenges, such as the need for precise control across various stages of tablet production. Ensuring tablet uniformity, consistent dissolution profiles, and minimal production downtime are critical considerations.
<h2>Facilitate efficient tablet compression</h2>
The PROTAB™ 300 by ACG World is a single rotary tablet press designed to bridge the gap between R&D and production-scale operations. This model is ideal for both small and medium-batch production, featuring an intuitive user interface and an interactive dashboard to streamline the tablet-compression process. The system includes an R&D turret capable of testing different formulations and tooling, which is easily scalable to larger production runs. Interchangeable turrets offer flexibility, allowing you to compress a variety of tablet sizes at different speeds. The lightweight, toolless design of the assemblies ensures mechanical changeovers can be completed in under 30 minutes, maximizing production uptime. Additionally, the PROTAB™ 300 is equipped with InstAmend technology for faulty punch detection and rectification, reducing long process interruptions and increasing efficiency. The sophisticated feeder design minimizes leftover powder, reducing valuable formulation loss to less than 50 grams.

Single rotary tablet press for small and medium-batch production

Formulation technologies are an integral process in many industries such as pharma and food. Chemical mixtures require strict handling to combine the separate ingredients into the homogenized recipe that makes your final product. Formulation technology stores, mixes and subjects the elements to a range processing parameters according to your specifications to develop the base material. The resulting formulas are then weighed, formed, packaged, or sent for further formulation.

Formulation

Drawing samples and testing them for conformity with preset quality standards allows manufacturing units to produce a consistent quality of the product. In a batch process, sample testing systems ensures that each batch meets the specified standards. In a continuous process, product and materials testing helps in the early identification of quality issues, saving significant time and resources, and preventing a sub-standard product from reaching the market. The selection of industrial testing equipment depends on the identification of key quality parameters. These parameters may include volume, weight, viscosity, hardness, particle size distribution, sterility, gauge and containment, among other parameters. Testing machinery need regular calibration to ensure that the parameters being tested are accurate. Some of the more common testing solutions include thermal imagers, scratch testers, optical inspectors and texture analyzers.

Testing

When producing pharmaceutical or nutraceutical tablets, achieving precision in weight, thickness, and overall consistency is critical. Manual methods can be time-consuming and prone to errors, especially with complex formulations or high production demands.
<h2>Automates tablet compression for consistent production</h2>
The LEGACY 6100 by ACG World is a single-rotary fully automated tablet compression system designed to meet the stringent quality requirements of the pharmaceutical markets. It stands out with its capacity for comprehensive applications such as compressing granules and Multiple-Unit Particulate Systems (MUPS) into monolayer tablets. Featuring the largest feeder coverage in its class (up to 9 feeders), it ensures accurate dosing and reliable high-speed production. The interchangeable turret design enables quick tool changes, accommodating a variety of tablet shapes and sizes, thereby enhancing production flexibility. The patented PARAMOUNT turret achieves up to a 27% increase in output. It also includes the industry's largest compaction rollers (290 mm in diameter) to provide effective compression through increased dwell time. The system supports challenging formulations, including those with abrasive, corrosive, or poor-flowing ingredients, and ensures uniform tablet quality with minimal segregation and crushing. It effortlessly integrates accurate single sorting, sampling, and rejection processes, ensuring output consistency at rated RPMs.

Single rotary tablet press

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

Industrial sampling equipment are systems that allow manufacturers to test (in other words to take a sample of) the products they are manufacturing. This process is generally implemented as a means of quality control but it can also be used as a mean to ensure that production processes adhere to certain regulatory standards. Quality control in your manufacturing process starts with precision sampling techniques. Automated systems deliver consistent samples at a pre-set rate for accurate testing and probing. Sampling technology uses a calibration system involving a series of sensors to extract the material at high levels of reliability.

Sampling

Sorting is the process of arranging items systematically, using a specified criterion, to categorize and group similar items and identify non-conforming items for removal. The choice of a sorting machine depends on the type of item to sort, the sorting criteria, the number of categories that the items need to be sorted into, sorting speed, and accuracy. Sorting machines can be used in the food processing industry for sorting and categorizing fruits, vegetables, empty bottles, crates, and other items; other examples include sorting of tablets and capsules by weight for quality control in the pharmaceutical industry. As well as sorting waste in the recycling industry. Manual sorting is a laborious task however, with the use of specialized equipment, manufacturers are able to automate their sorting at high speeds.

Sorting

In industries where precise particle size reduction is crucial, traditional milling methods may not offer the required control or efficiency. Achieving uniform particle size while minimizing heat generation can be challenging, especially for heat-sensitive materials.
<h2>Achieve consistent particle sizes by adjusting screen and impeller</h2>
The Hanningfield Uni-Mill B-Series is an over-driven conical mill designed for applications requiring precise particle size reduction. Utilizing a belt-driven impeller rotating inside a screen, the mill achieves comminution by compressing and shearing particles between the impeller and the screen surface. Available in various models, the Uni-Mill B-Series accommodates different throughput rates, from 360 kgs/hr with the M10-B model to 7200 kgs/hr with the M60-B model. Constructed with 316L stainless steel for contact parts and 304 stainless steel for non-contact parts, the mill meets FDA compliance standards. It supports several customizations like temperature monitoring, CIP, WIP, and ATEX execution, making it suitable for dry and wet milling applications in pharmaceutical, food, chemical, and nutraceutical industries.

Over-driven conical mills for precise particle size reduction

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

Shearing

Size reduction

In ethylene oxide and glycol (EO/EG) production, the need to efficiently recover valuable ethylene from purge gases is crucial. Inefficient recovery methods can lead to significant material losses and increased operational costs, impacting the overall productivity of the process.
<h2>Recover ethylene from cycle gas purge</h2>
The BORSIG Ethylene Recovery Unit is a specialized system designed for ethylene oxide and glycol (EO/EG) production. This unit enables the recovery of valuable ethylene monomer from the cycle gas purge, which is essential for optimizing resource utilization and minimizing waste. The process starts with the purge gas entering an inlet filter to remove droplets before moving to the hydrocarbon-selective membrane stage. Here, ethylene is separated from argon and nitrogen. The ethylene-rich stream is directed to the suction side of the reclaim gas compressor, while the ethylene-depleted stream is routed to the boiler unit. The unit features a package design for quick installation and easy implementation. It ensures safe operation with high reliability and low maintenance, offering a short return on investment period.

Ethylene recovery unit for ethylene oxide and glycol production

In pharmaceutical and chemical manufacturing, certain raw materials cannot be processed in a dry state. These materials require a reliable method to form granules with uniform size and high solubility, mitigating dust and cross-contamination issues during processing.
<h2>Ensuring homogeneous and rapidly soluble granules</h2>
The MG Series from Alexanderwerk is a moist granulation system designed to process moist and pasty materials using counter-rotating cylinders. This system excels at producing granules with diameters ranging from 1.0 mm to 10.0 mm. Moist granulation involves adding a liquid to dry materials, forcing the mixture into a granulating extrusion cylinder, compressing it, and cutting it into granules. The MG Series is known for its quick disassembly, facilitating easy cleaning and maintenance. Models like the GA 65, G 1/100, G 1/168, and G 1/244 cater to different throughput needs, from 100 kg/hr to 2000 kg/hr. The process is essential in industries such as pharmaceuticals, chemicals, food, and nutraceuticals to ensure product uniformity and stability. Alexanderwerk's moist granulators are ideal for situations where air entrapment must be minimized and active ingredients evenly distributed.

Moist granulation system for pharmaceutical and chemical industries

Cutting

Granulation

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

Connect directly with world leading manufacturers of Compression equipment and find technology to build or improve your production line.