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Mixing and fluid bed granulation

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. Drying technology exploits the modes of industrial heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Fluid bed dryers use a stream of hot air to reduce the moisture content of powders and granules. This principle is often used for the production of high-quality pharmaceutical powders as well as the production of animal feed, minerals, sand, and dairy products.

Continuous

A mixing &amp; fluid bed granulation system is the combination of a fluid bed dryer and a high Impact mixer. If you have a high-capacity continuous powder process where you need to mix various powders with liquids, agglomerate and then dry the granules, such a combined system may be the best way to go.


<h2>Continuous mixing, agglomerating, drying and cooling</h2>
The Schugi® Flexomix agglomeration system is a combination of two proven Hosokawa Micron technologies: the Flexomix continuous mixer and agglomerator, and the Schugi® fluid bed dryer and cooler. This combined design provides optimal process control and makes this combination the ultimate powder processing solution. The system is controlled using a state-of-the-art integrated control system based on PLC and SCADA systems. It produces instant agglomerates with an open, raspberry-like structure, good solubility and good flow characteristics. Moreover, it has been designed as a stationary unit without any moving parts making it perfect for scaling up to almost any size. The system is suited for powders, granules, agglomerates, and pellets. Often used in the food industry, pharmaceutical and chemistry.

Industrial mixing is used to combine a heterogeneous mix of two or more solid, liquid or gaseous ingredients into a homogenous product. The choice of a suitable mixing solution depends on the physical state of the ingredients and the desired mixing process; the sensitivity of the ingredients and process temperature and pressure requirements are also important factors.

Mixing

solid

In a Fluid Bed, a product or solid is made fluid by an upward moving flow of gas. The mechanical movement of the Fluid Bed strengthens this effect. Thus, the gas and product are intensively mixed so that high heat transfer and an optimum physical reaction speed are achieved.


<h2>Continuous fluid bed dryer for an energy-efficient drying</h2>
Ventilex Continuous fluid bed dryers apply world-leading fluid bed technology to high-throughput bulk processes. By choosing a good combination of gas speed and mechanical movement, you will be able to process granular products with a wide range of grain sizes while forming a minimum amount of dust.

A whole range of products can be processed in the fluid bed for long residence times, up to two hours per machine are possible. Ventilex Fluid bed dryer can function at temperatures from–15ºC to +600ºC. The gas speed can vary from 0.2 to 3m/sec.

Continuous fluid bed dryer

Batch

<span style="font-weight: 400;">Designed for pharmaceutical R&amp;D, a lab-scale fluid bed dryer and mixer/granulator combination provides a value-for-money solution that allows for economical yet scalable production of oral solid dosage compounds.</span>
<h2>Flexible R&amp;D fluid bed system for economical production of pharmaceutical powder doses</h2>
<span style="font-weight: 400;">Available in a range of batch sizes, the Sejong Pharmatech D5Lm drying and mixing machine has been designed for the economical preparation of lab-scale quantities of dry compounds.</span>

<span style="font-weight: 400;">With options for 1l, 3l and 5l capacity, the D5Lm can be specified to meet your exact requirements. Touchscreen controls with full schematic status indication provide easy visibility of the machine status and simple operation. The control system is fully 21CFR part 11 compliant.</span>

<span style="font-weight: 400;">With lower power consumption that two separate units, and only one air supply required, the D5Lm combined dryer/mixer unit is an economical lab or small batch production system.</span>

Fluid bed dryer and mixer for lab scale

liquid

<span style="font-weight: 400;">Fluidised bed drying (FBD) is a common process in the pharmaceutical industry for drying compounds to achieve the required moisture content, as well as applying coatings or binders before further processing prior to tablet formulation. For R&amp;D work a fluid bed dryer with economical batch sizes is required, but it must also be able to scale up successfully for satisfactory full-scale production.</span>
<h2>Flexible lab-scale fluid bed dryer/granulator with advanced features</h2>
<span style="font-weight: 400;">The Sejong Pharmatech D5L is a compact small-scale fluid bed dryer/granulator with features specifically designed for lab work and small batch processing in volumes from 1 to 5 litres.</span>

<span style="font-weight: 400;">The D5L features both top and bottom spray arms for maximum flexibility, with fully adjustable height control for both. This allows the machine to be used for drying, granulating and coating.  The product container is ergonomic to use and makes adding and discharging compounds quick and simple, and the capacity is fully controllable based on the required production volume. The container also features a built-in sampler, to allow physical inspection of the progress of the cycle as it runs - perfect for R&amp;D situations.</span>

<span style="font-weight: 400;">The D5L features a full colour touchscreen with easy-to-read schematics for control and diagnostics, allowing the operator to monitor all parts of the cycle. All control software is fully 21CFR part 11 compliant.</span>

<span style="font-weight: 400;">The exhaust features a dust collection system with easy-to-change cartridge filter system, and the unit features a powerful 4.8kW electric coil heat exchanger for precise temperature control.</span>

Fluid bed dryer for lab scale

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

Separation process to separate components of a liquid mixture, for recovering dissolved solids from liquids. 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 are widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high purity chemicals.

Separation

<span style="font-weight: 400;">Fluidized bed drying (FBD) is a common process in the pharmaceutical industry for drying compounds to achieve the required moisture content, as well as applying coatings or binders before further processing prior to the tablet formulation. For production-scale processes, a fluid bed dryer needs to be robust, easy to operate and flexible enough to handle continuous operation.</span>
<h2>Dry pharmaceutical compounds with increased control and reduced maintenance time</h2>
<span style="font-weight: 400;">The Sejong D Series is a production scale fluid bed dryer for use in the pharmaceutical industry, or in any scenario where powder fluid processes are required.</span>

<span style="font-weight: 400;">The D Series has been designed to offer a robust production unit with the highest levels of safety and operator ease of use. All valves, seals, flanges and weld points have been designed to be 12 bar pressure resistant. The ergonomic user interface uses graphical representations to allow a single operator to manage all aspects of the machine setup, running and discharge. Recipe systems allows full automation of the whole drying process, without user intervention.</span>

<span style="font-weight: 400;">The D Series filter system uses pulse blowback air to clear dust from the filters. This allows for a highly consistent fluid flow and can reduce the production time. For ease of maintenance, the in-built winch is computer-controlled to allow for quick and accurate filter maintenance.</span>

<span style="font-weight: 400;">For cleaning, the D series adopts a Clean in Place system using 3 low-flow rotary nozzles which are placed directly inside the body of the machine and powered by a high-pressure pump. This allows maximum cleaning performance with low water flow and minimal downtime.</span>

Fluid bed dryer for production scale

<span style="font-weight: 400;">A complete granulation line allows for the mixing and granulation of pharmaceutical compounds for the production of tablets. By linking fully compatible milling, mixing and fluid bed machinery with vacuum conveying it provides a turnkey solution for preparation of powder doses ready for pressing into tablets.</span>
<h2>Complete solution for preparation of granular pharmaceutical compounds for tablets</h2>
<span style="font-weight: 400;">Sejong Pharmatech’s Granulation Line is the most cost-effective way to achieve a turn-key granulation solution for the manufacture of pharmaceutical compounds for tablet preparation.</span>

<span style="font-weight: 400;">The granulation line consists of the Sejong CM series production scale conical mill, the Sejong M series production-scale speed mixer, the Sejong D series production scale fluid bed dryer and an optional vacuum conveyor system for the creation of a completely closed line environment.</span>

<span style="font-weight: 400;">Designed for total compatibility, these devices work together seamlessly to provide the perfect input for tablet pressing machines. When buying as a line package, significant cost savings can be made compared to sourcing individual machines.</span>

<span style="font-weight: 400;">The optional vacuum conveyor removes the need for manual handling between processes, and ensure a clean and safe transfer of powders between process stages.</span>

<span style="font-weight: 400;">All the Sejong machinery is manufactured with ergonomics and ease of use in mind, and the touch screen HMI’s are fully 21CFR part 11 compliant.</span>

Granulation line of mixer and fluid bed dryer

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

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

A granulator is a high-speed knife mill designed to cut down large components of feedstock and reduce them to smaller particle sizes. Selecting the right scissor geometry and configuration allows granulators to process plastic bottles, organic fibers, films, wires, cables, and other difficult materials. Agglomeration granulators combine fine particles into larger granules by creating bonds between them. Bonds are formed by compressing fine particles or through the use of a binding agent. Granulation is used extensively in the pharmaceutical industry to prevent segregation of the constituents of a powder mix.

Granulating

Fluid bed dryers

Croutons

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

Sugar coated nuts

Roasted nuts

Softgel capsules fast-track the delivery of medication to the bloodstream. Unlike solid pills, they do not need to be broken down by the body before the drugs can be absorbed. Moreover, they are optimal vehicles for oils and fat-soluble formulations that cannot be compressed into tablets.

Softgel capsules

The two-piece capsule is a visual shorthand for all types of medical remedies. Advances in technology have made the production of hard-gelatin capsules a convenient delivery method for drugs and other ingested substances. But the simple solution requires micrometric precision to be manufactured to the proper pharmaceutical standards.

Hard gelatin capsules

The nonproprietary name for HPMC – hydroxypropyl methylcellulose – is such a mouthful that it has two abbreviations. Hypromellose is the other one. The non-ionized material offers a safe alternative to gelatin capsules, especially as most common API and excipients are suitable HPMC capsule ingredients.

HPMC capsules

Multilayer tablets are a popular fixed-dose combination (FDC) offering a range of release profiles. Multilayer tablet technology solves challenges to API consistency, allowing manufacturers to develop formulations from incompatible ingredients.

Multi-layer tablets

It is strange how two tablets can belong to the same but at the same time to a different category depending on how the tablet itself is classified. For example, chewable tablets and effervescent tablets have two different routes of administration but both belong to the category of uncoated tablets. Uncoated tablets are prepared by compression of granules in which no coating is added after compression. They may be single-layer or multi-layer tablets.

Uncoated tablets

There are slight differences between human and animal pharmaceuticals, but that dissimilarity is enough to create new production challenges. Veterinary tablets formulation reflects the diversity of enzymes that different species use to break down substances. Although the methods involved are comparable to human drug manufacturing, equipment and processes need to adapt to a wider dosage variability in veterinary tablets.

Veterinary tablets

Elderberry falls squarely in the category of superfoods. Every part of the plant (flowers, berries, and bark) is loaded with vitamins, antioxidants, bioflavonoids, and other compounds. However, cyanide in the plant could be lethal if consumed raw, making elderberry extraction processing complex.

Elderberry extract

It took the scientific community almost 70 years to agree on the name ‘protein’ and discard the popular alternative, proteid. But protein powder processing still needed another five decades to be commercialized in the 1950s. Once extraction and purification could be industrialized, protein powder soon became a basic staple supplement.

Protein powder

Laundry detergents are currently on the rise due to increasing urbanization and the need for automation. The global market will reach $98,139.7 million by 2030 from $61,711.0 in 2020, influencing the demand for laundry detergent equipment. Unlike in Western countries, powdered detergents are more popular in Asia and China because they’re cheaper.

Laundry detergent

Powder detergent is one of the most widespread washing solutions used in the laundry of fabrics. Since they contain no water, powder detergents are lighter than liquid detergent or pods, which results in cheaper transport and, thus, a more affordable choice for the end consumer. Although manufacturers can formulate their powder detergents differently, the detergent powder production process relies on a combination of builders, surfactants, and enzymes.

Powder detergent

Poultry feed

The fishmeal powder market forecast shows that its global market value will reach USD 10.3 billion by 2025. Expanding since 2019, at an annual growth rate of 6.5%. Fishmeal powder production has strong business potential with the increase of applications in animal feed, pet food, and fortified foods.

Fishmeal powder

Kaolin, also called china clay, is made from natural rock composed of aluminosilicate clay or kaolinite. Kaolin has wide applications in different industries. Moreover, their classification depends on their industrial use, which includes film formation, fiber extension, polymer extension and chemical composition. Choose a kaolin processing machine to help you make kaolin for beauty products, paper filler, coating, ceramics and even medicine.

Kaolin

In Ancient Egypt, starch production was used mainly for coating and gluing the papyrus sheets. Today, the paper industry still uses the same technique even if starch processing equipment has changed immensely. But besides shiny reams, starch has a fundamental place in the food and beverages industry.

Starch

Ancient civilizations were using yeast as it naturally occurred in bread-making and brewing. But yeast processing equipment wasn't developed and fully commercialized until the end of the 18th century. Today, this industrialized micro-organism is critical in producing biofuels and other products beyond food and drinks.

Yeast

Brewers' grain, also known as brewers' spent grain or BSG, is the residue of malt and beer production. This brewing by-product is sometimes wasted causing an important environmental impact, nevertheless, with the circular economy in mind, brewers' grain processing can turn waste into value mainly for the feed and food industry, tackling some of the sustainable development goals (SDGs).

Brewers grain

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