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large-scale-granulator

Large scale granulator

Cutting

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

Granulation

Granules

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.

For industries dealing with fine powdery products, transitioning to a more manageable form is critical. Problems like poor flow properties, dust generation, and inconsistent dosing can hinder efficient processing.
<h2>Transform powders into free-flowing granules</h2>
The compaction and granulation technologies from Hosokawa Alpine are designed for transforming powdery chemical, pharmaceutical, mineral, and metal products into compacted shapes. Utilizing methods such as compaction, dry granulation, high-pressure roller grinding, briquetting, or pelletizing, these technologies improve product characteristics like bulk density, flowability, and dosing accuracy. This results in dust-free granules that streamline subsequent processing steps. Suitable for multiple industries, these technologies reduce common issues associated with fine powders, enhancing overall operational efficiency.

Compactors and granulators for powdery products

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

Pelleting equipment transforms powdered, mashed, or grounded material into a denser cylindrical shape. Pellet processing compresses the fine material against a perforated die, where it will be shaped and cut. Although granulating and extrusion also produce pellet-like products, manufacturing pellets is a distinct process.

Pelleting

Powder

solid

Continuous

Industrial

In industries like chemicals and foodstuffs, converting liquid raw materials into solid granules can present challenges such as dust formation and uneven particle size. This calls for a reliable granulation system to ensure efficient conversion and high-quality output.
<h2>Convert liquid materials to solid granules effectively</h2>
The Fluidized Bed Spray Granulators WS-GT from Allgaier Process Technology are designed for efficient production of solid, dust-free granules from liquid starting materials such as suspensions and solutions. By applying the liquid via nozzles to the fluidized bed, the system promotes even particle growth as the drying air evaporates the water content, resulting in dimensionally stable granules with excellent flowability. The granules are then classified by size through a screening machine or sifter, while undersized particles are recycled back into the process. This granulator is particularly effective for producing urea granules, yeast and gelatin granules, and water jars. The system's high performance and possibility for explosion-proof configurations ensure safe and reliable operation.

Fluidized bed spray granulators for liquid to solid conversion

Classifying

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

Recycling

Screening

In industrial recycling processes, handling large volumes of plastic waste efficiently and effectively is crucial. The challenge is to reduce the size of high-density plastic parts to a consistent granule size, maximizing the use of recycled materials in production.
<h2>Process large parts with customizable cutting chambers</h2>
The central granulators from AEC (ACS Group) are designed to process large volumes of plastic parts. These granulators feature configurable cutting chambers, which can be adjusted to handle parts with higher density. Different geometries, including tangential and offset, are available to tailor the granulator to specific process needs. The high-quality output ensures that a maximum amount of recycled material can be efficiently reintegrated into the production process. The flexibility and precision provided by AEC central granulators make them suitable for diverse industrial applications, improving overall recycling efficiency.

Central granulators for high-volume plastics recycling

Handling

Size reduction

In injection molding or extrusion operations, there is often a need to reclaim resin efficiently right at the production site. Managing this process without interrupting production cycles or increasing labor costs is a common challenge.
<h2>Reclaim resin efficiently beside the press</h2>
The AEC family of Beside-the-Press Granulators is designed for seamless integration into any molding or extrusion operation. These granulators come in various models, accommodating specific needs for resin reclaim directly at the side of the press. Equipped with or without screens, they ensure flexibility in processing materials. The durable construction and high-performance capabilities make them suitable for continuous operation. Each model emphasizes ease of use and low maintenance, minimizing downtime and operational interruptions. These granulators are ideal for efficiently reducing scrap material into re-usable granules, contributing to cost savings and sustainable operations.

Beside-the-press granulators for injection molding

Grinders use a spinning blade or rotating abrasive elements to reduce the size of various materials. The specifications, RPM and grit of the engineered grinder, will result in various particle sizes. As a result, what you want to make will determine the type of grinder you need. Grinding is used for improving the texture and flow properties of various products and to enhance the flavor of food products such as coffee, spices, sugar, nuts, sesame, poppy seeds, lentils, wheat, and rice. Choosing the right rotational speed, grinding elements, and processing power allow the grinding and shredding of a wide range of materials into coarse or fine powders. Popular types of heavy duty grinders in food processing include angle grinders, bench grinders and meat grinders.

Grinding

In food processing, feed production, and fine chemical manufacturing, achieving uniform particle size distribution and stable product quality is critical. Complexity arises when trying to combine multiple processing steps like granulation, drying, and cooling in a single continuous operation.
<h2>Achieve uniform granulation and high flexibility</h2>
The Glatt GF Series fluid bed granulators offer a solution tailored for continuous granulation, drying, and coating processes. These granulators feature an elongated, rectangular fluidized bed, allowing for targeted material movement through various zones. Each zone can have different process conditions, such as flow rates and temperatures, enabling seamless transitions between granulation, drying, and cooling. The design's flexibility includes multiple nozzle arrangements, internal filters, and modular assemblies, making it adaptable to specific production needs. The equipment is suitable for industries like food, feed, and fine chemicals, and it comes with options like high supply air temperatures for chemicals or hygienic designs for food applications.

Fluid bed granulator for food and chemical industries

To coat your consumer products with color or taste-enhancing substances, specialized technologies are available that ensure all the contents are individually and evenly covered. The process starts with loading your goods onto rotating drums, exposing the products to spray nozzles that treat them with your prescribed coating formula.

Coating

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

In high-capacity industrial processes, managing large volumes of material while ensuring efficient size reduction is critical. When handling low-density fibers or heavy purgings, robust systems are essential to maintain productivity without compromising on performance.
<h2>Tackle the toughest granulation tasks</h2>
The Heavy Duty Granulators from AEC (ACS Group) are engineered for demanding applications requiring efficient size reduction for a variety of materials. These granulators feature a versatile design accommodating low-density fiber to heavy purgings, ensuring they are equipped to handle high-capacity throughput needs. Designed with durability in mind, these granulators come with an extensive range of models and options to meet specific process demands. The heavy-duty series is renowned for its robust construction and ability to maintain consistent performance even under the most challenging conditions.

Heavy duty granulator for high-capacity size reduction

Crushing is the process of applying an amplified force to a material to break it down into smaller pieces. A crusher is a machine designed to crush large chunks of material into smaller bits or a powder. They are used to reduce mineral rocks to smaller rocks, gravel, or dust. They are also used to reduce the size of waste materials for easier disposal/recycling or to reduce the size of a solid mix of raw materials. Crusher equipment selection depends on the physical properties of the material to be processed, the in-feed size, and the desired output particle size.

Crushing

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.

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Dry granulator for pharmaceutical powders

In pharmaceutical production, achieving precise mixing and granulation of powder ingredients is crucial to ensure product quality and consistency. Traditional methods often struggle to prevent powder sticking and contamination, leading to inefficiencies and potential product losses.
<h2>Optimal shear for consistent granulation</h2>
The ROTO MIX by IMA is a latest-generation high shear mixer granulator specifically designed for the dry mixing of powders and wet granulation in the pharmaceutical industry. Inspired by the proven Roto technology, it ensures the optimum shear for granulation at all speeds. The mixer uses a unique impeller and chopper combination along with a liquid binder distributor to achieve efficient mixing and agglomeration. Its design minimizes powder sticking, thereby maximizing product yield. The through-the-wall installation optimizes room layout and integrates seamlessly with other granulation equipment. Additionally, the in-line dry milling enables wet granule sizing and direct transfer to a fluid bed dryer. Equipped with strategically positioned washing nozzles, the system also offers Wash In Place (WIP) capabilities, ensuring thorough cleaning even in hard-to-reach areas.

High shear mixer granulator for pharmaceutical applications

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

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

A loading system feeds your continuous or batch processing machine with the specified material or item in line with the flow of production. Loaders transfer the articles from one stage of preparation to the next with uniformity and accuracy.

Loading

Batch

In the chemicals industry, achieving dust-free, uniformly sized granulates is crucial for applications like additive manufacturing and dry flue gas cleaning. Traditional methods often fall short in maintaining consistency and quality, presenting a significant challenge for production lines focused on efficiency.
<h2>Form and round cylindrical stable pellets</h2>
The Gear Pelletizer AGF from Hosokawa Alpine is designed to form cylindrical, stable pellets with uniform length. Utilizing counter rotating hollow toothed rollers, the AGF Gear Pelletizer processes materials into granulates with diameters between 1 to 10 mm. For creating shingled, highly porous granulates, the Bextruder compresses material through an extrusion rotor and perforating die. The Bexroller further refines these granulates, rounding them off in a spheronization process. These pieces of equipment are integral in industries that require precision and reliability, particularly in chemical, food, and pharmaceutical applications. The systems are known for their efficiency and low-maintenance operation, ensuring high-quality end products with minimal dust.

Pelleting and spheronizing equipment for chemical granulates

The extruder was first developed to make lead pipes in the late 18th century. But the extrusion process technique quickly spread to other manufacturing sectors, including food, feed, and biomass products. An extruder machine presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the premixed feed material through a barrel. Thermal pressure applied in this step can chemically modify the mixture, so the screw system must be precisely calibrated to achieve the desired result. Finally, a knife head cuts the extruded material into your designed dimensions. Extrusion machinery produces items of a uniform size, shape, and consistency.

Extrusion

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

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

Refining

Entry level

Pilot

When developing new products with unpredictable grinding properties, the need for flexible systems is paramount. Traditional setups may involve multiple mills and classifiers, taking up significant space and often reducing efficiency during production and research phases.
<h2>Integrate multiple grinding processes seamlessly</h2>
The Multiprocessing System by Hosokawa Alpine offers a versatile solution for flexible production and research requirements. This system integrates multiple mill types into a single compact unit, ideal for rapid changeovers and efficient space utilization. By allowing quick switching between various grinding and classifying modules, it supports small-batch R&D while maintaining compliance with GMP standards. The system is available in sizes ranging from small laboratory setups to large-scale production units. Key features include modular design, optimized dismantling for easy cleaning, and minimal documentation requirements. Ideal for industries such as food, chemicals, pharmaceuticals, and minerals, the Multiprocessing System ensures high flexibility, reduced investment costs, and ease of validation.

Multiprocessing system for flexible research and production

When dealing with voluminous plastic waste, achieving high throughput rates and efficient recycling processes is critical. Common challenges include handling various shapes and materials while ensuring consistent particle size reduction and minimizing downtime.
<h2>Handle tough plastic waste efficiently</h2>
The Rotoplex Ro from Hosokawa Alpine is an industrial granulator renowned for its durable design and efficiency in processing all types of plastic waste. This granulator features a patented cross-scissor cut rotor and a solid spheroidal graphite cast iron design, ensuring robust and reliable operation even under continuous heavy-duty conditions. Specific designs enable it to accommodate high cutting forces and throughput rates, making it suitable for various applications, including cable scrap, rubber, and fibre waste. The Rotoplex Ro is available in sizes ranging from 15 to 500 kW and can be adapted with either standard or tangential chutes for optimal feeding characteristics. Additionally, it offers easy cleaning and maintenance due to its removable cover and accessible cutting chamber. Stator knives can be used on four sides while rotor knives can be used on one side, extending the service life and reducing operational costs.

Industrial granulator for high-throughput plastic recycling

In the plastic recycling industry, reducing large volumes of waste materials efficiently while minimizing dust generation is essential. Challenges include the effective comminution of moldings, blow moldings, and sprues without creating excessive waste or requiring frequent maintenance.
<h2>Efficiently reduces plastic waste with minimal dust</h2>
The Polymer-Line PL from Hosokawa Alpine is a specialized granulator designed for low-dust and cost-effective comminution of plastic parts. Its innovative cutting chamber geometry ensures excellent product intake and efficient size reduction. A cross-scissor-cut rotor reduces energy consumption and dust generation, making the process more efficient. Additionally, the rotatable screen and stator knives, usable on four sides, extend the equipment's operational life. Designed for large volume and bulky plastic parts, it’s suitable for both ancillary and central mills applications.

Low-dust granulator for plastic parts recycling

Comminution

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

Dealing with the comminution of various plastics, films, and other cuttable products in a cost-effective manner poses significant challenges. Ensuring uniform particle size distribution, high throughput rates, and energy efficiency are key factors in achieving optimal results.
<h2>Efficient plastic granulation with optimal accessibility</h2>
The Compact-Line CL by Hosokawa Alpine is designed for efficient comminution of various plastics and films. Featuring a rotor with Alpine's patented cross-scissor cut technology, it ensures high throughput rates while reducing energy consumption. The electrohydraulic opening mechanism allows easy access for cleaning and maintenance. The adjustable and re-sharpenable knives minimize spare part requirements and operational downtime. Available in sizes ranging from 30 kW to 500 kW, it caters to a variety of industrial needs with modern design features aimed at maximizing user benefits.

Compact granulator for plastic comminution

A shredder is used to reduce the size of various materials through the cutting action of its contra-rotating shredding rollers or knife shafts. Industrial shredders come in many different designs, sizes, and variations. Shredders are best used for the disposal of used tires, scrap metal, car wrecks, garbage, recycling of plastics, paper, and shredding of various foods such as cooked cereals. The choice of a suitable heavy duty shredder depends on the properties of the material to be processed, the desired shred size, the size of the in feed material, and the volume of material to be processed.

Shredding

Manufacturing facilities often face challenges when preparing complex raw material mixtures that require thorough homogenization and precise water integration. Inconsistent mixing can lead to poor product quality and increased waste, which is costly and time-consuming.
<h2>Ensures homogeneous mixing with precise water dosing</h2>
The Raw Material Mixer SRM from Hebenstreit is designed specifically to handle complex raw material mixtures efficiently. Operating horizontally, it mixes ingredients and water thoroughly, ensuring a homogeneous blend. Equipped with an automatic water injection system, it allows for water addition during the mixing process to maintain consistency. The mixer has a speed of up to 1500 rpm and includes a granulator to crush agglomerates, which can be controlled via a display. This makes it particularly suitable for snack production processes such as raw material preparation, extrusion, drying, seasoning, cooling, co-extrusion, cutting, embossing, and conveying. Ideal for applications where granulated raw materials and uniform moisture distribution are crucial.

Industrial raw material mixer for complex recipes

Blending

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

In specialized production environments, maintaining the stability and consistency of temperature-sensitive materials during granulation can be challenging. This is particularly true when dealing with highly viscous solutions or precise mixing requirements in continuous operations.
<h2>Streamline granulation and drying processes</h2>
The Glatt fluid bed plants type AGT® are designed for continuous spray granulation, providing an optimal solution for the food, feed, and fine chemical industries. These plants feature a circular single-chamber design, which allows for the simultaneous drying of liquid raw materials and granulate formation in an ideally mixed fluidized bed. The system combines high process flexibility and adaptability with interchangeable process chambers, allowing for operations like spray granulation of liquids, powder agglomeration, and coating. The AGT® series supports both continuous and batch-controlled operations, making it versatile for various applications. Its controlled environment ensures consistent particle size and effective mixing, while options such as different nozzle systems, flexible solids feeders, and adaptable filters enhance its utility.

Fluid bed granulation system for food and chemical industries

Agglomeration

liquid

In the production of powders and granular materials, achieving precise mixing and granulating is essential to meet industry standards. Traditional methods often fail to provide uniform mixing, leading to inconsistencies in product quality and increasing operational costs.
<h2>Achieve consistent and precise powder mixing</h2>
The VAS Pulver by GLASS Maschinen is a high-speed mixer designed specifically for mixing and granulating powders to perfection. Available in various capacities ranging from 80 to 2200 litres, it offers flexibility for diverse production needs. This mixer features an automatic lid operation and a motor-driven swivelling drum, ensuring ease of use and efficient operation. The drum's discharge height can be customized according to user requirements, and the EasyClean drain valve allows for quick and efficient cleaning. With the option of chopper configurations including double-U shape or knife head, the VAS Pulver is designed for precise granulating and mixing. Integrated temperature control, direct steam injection, and an integrated vacuum pump enhance the functionality, making it suitable for high-standard hygienic applications. The equipment also complies with EHEDG guidelines, ensuring adherence to the latest hygienic engineering standards.

High-speed mixer for granulating and mixing powders

Manual

In pharmaceutical and industrial applications, forming medium to high-density granules from powders is often challenging. Precise control and uniform mixing are essential to ensure high product quality and efficiency.
<h2>Facilitates homogeneous wet granulation</h2>
The GMX GRANUMEIST® is a high shear granulator and mixer designed by Freund for the efficient and homogeneous wet granulation of powders. Its top-drive design enhances user safety and enables faster processing times. The removable bowl and mixing blade with a fixed bowl lid allow for superior cleaning and maintenance. The vertical shaft chopper improves granulation, while the user-defined mixer and chopper speeds offer processing flexibility for both aqueous and solvent materials. Optional features include vacuum drying for one-pot processing and a jacketed bowl for product temperature control. The system is equipped with a color touch screen control for validatable process control, configuring both automatic and manual modes. It also supports 21 CFR Part 11 compliant data and recipe handling. The GMX GRANUMEIST® series comes in various models, offering bowl capacities from 150 to 1200 liters.

High shear wet granulation line

In pharmaceutical manufacturing and other powder processing industries, achieving uniform granule density and size is crucial. Traditional mixing methods often struggle with consistency and efficiency, leading to variations in the final product quality.
<h2>Rapid and uniform granulation</h2>
The GMX-LAB Mini GRANUMEIST® from Freund is a high shear wet granulation system designed to provide consistent and efficient granulation of powders. Its top-drive design facilitates easy cleaning and maintenance, ensuring faster processing times and enhanced safety. This granulator features interchangeable 4L and 8L bowls, user-defined mixer and chopper blade speeds, and an integrated peristaltic pump for precise solution addition. The system can handle both aqueous and solvent processing with optional jacketed bowls for temperature control. Its quick-change design requires no tools and is mounted on casters for easy maneuverability, making it an ideal solution for flexible and scalable production needs.

Mini High shear granulator for wet granulation

Achieving consistent and homogenous granulation of powders is crucial in pharmaceutical and chemical manufacturing. Traditional methods often struggle with inefficiencies, extended processing times, and intricate maintenance, making innovation in wet granulation technology necessary.
<h2>Ensures consistent and homogenous wet granulation</h2>
The GMX-LAB Micro GRANUMEIST®, from Freund, is a state-of-the-art high shear granulation system designed to streamline the wet granulation process for powders. Its top-drive design facilitates easy cleaning and maintenance, while ensuring faster processing times and enhanced user safety. With interchangeable 1L and 4L bowls, it offers processing flexibility and accommodates varying batch sizes. User-defined settings for mixer and chopper blade speeds, along with an integrated peristaltic pump, provide precision in solution addition. An optional jacketed bowl allows for precise product temperature control. The Smart-Safe™ containment option adds an extra layer of security, and the color touchscreen control system supports validatable process control with various end-point detection parameters. This system is well-suited for industries requiring medium to high density granules, including pharmaceuticals and chemicals.

High shear lab granulation system for powder processing

Dispersing systems are used to produce emulsions of two immiscible liquids or dispersions of solid particles in a liquid medium. The mixers generally operate on the rotor/stator principle and apply a high shear force on the suspended particles to break them down. The choice of a dispersion mixer depends on the physical state of the material being dispersed, the continuous or batch nature of the process, desired particle size, and the viscosity of the mixture. Dispersion mixers are widely used in the food industry for the dispersion of solid ingredients in oil or water and in the coatings industry for the dispersion of pigments.

Dispersing

When producing pharmaceuticals or food products, achieving a homogeneous wet granulation of powders is crucial for consistent product quality and process efficiency. Processing powders into medium to high-density granules requires a granulation system that ensures rapid mixing and uniform consistency.
<h2>Enhanced wet granulation with flexible bowl capacities.</h2>
The GMXB-Pilot GRANUMEIST® by Freund is a high shear granulator designed for efficient and homogeneous wet granulation of powders. It features a bottom-drive system that enhances user safety and simplifies maintenance. The modular design allows for interchangeable product bowls in capacities of 10L, 25L, and 65L, catering to various batch sizes. An integrated peristaltic pump and user-defined settings for mixer and chopper blade speeds provide operational flexibility. Optional features include a jacketed bowl for temperature control and vacuum drying for one-pot processing. The system is equipped with a color touchscreen control system with both automatic (recipe driven) and manual modes, ensuring process control. Data can be collected via a USB port, and the system supports 21 CFR Part 11 compliance for data and recipe handling. The GMXB-Pilot GRANUMEIST® is suitable for pharmaceutical, nutraceutical, and food industries, offering scalable granulation solutions from lab to production scale.

Pilot High shear granulator for wet granulation

In the pharmaceutical and chemical industries, achieving a consistent particle size and density during wet granulation is crucial. Traditional granulation methods can present challenges such as long processing times and difficult maintenance, affecting production efficiency and output quality.
<h2>Enhance wet granulation efficiency and uniformity</h2>
The GMXB-LAB Mini GRANUMEIST® by Freund is a bottom-drive high shear granulator and mixer designed for efficient and homogenous wet granulation of powders. This system features interchangeable product bowls with capacities of 4L, 6L, and 10L, allowing for flexibility in processing different batch sizes. Its bottom-drive design simplifies cleaning and maintenance, resulting in faster processing times and improved user safety. The system includes user-defined settings for mixer and chopper blade speeds, an integrated peristaltic pump, and optional features such as a jacketed bowl for product temperature control and vacuum drying for one-pot processing. The GMXB-LAB Mini GRANUMEIST® allows for both aqueous and solvent processing, supporting a wide range of granulation requirements. Furthermore, the system features a color touchscreen control system with validatable process control and multiple endpoint detection parameters, ensuring consistent and reliable results.

High shear granulator for wet granulation of powders

In pharmaceutical production, achieving uniform granules with controlled density is crucial for consistent tablet formulation. Traditional granulation methods can often result in uneven particle sizes and inefficient processing times.
<h2>Facilitates efficient wet granulation with user-defined settings</h2>
The GMXB-LAB Micro GRANUMEIST® by Freund is a bottom-drive high shear wet granulation mixing system designed for homogenous granule formation. Its design allows for faster processing times and easy cleaning and maintenance, ensuring superior user safety. The interchangeable product bowls range from 1L to 6L, enabling process flexibility with both aqueous and solvent processing. User-defined settings for mixer and chopper blade speeds, as well as an integrated peristaltic pump, provide tailored granulation control. The Smart-Safe™ containment option and proportional mixer blade tip speeds add to the equipment's efficient and safe operation. The system also features a jacketed bowl for optional product temperature control and a color touchscreen control system with validatable process control and USB data collection port.

High shear GMP wet granulator

In pharmaceutical or chemical manufacturing, obtaining uniform granules with specific density and size is critical. Traditional granulation methods can lead to uneven granules, prolonging production times and complicating downstream processes.
<h2>Create uniform granules with precise control</h2>
The GMXB GRANUMEIST® from Freund is a high shear granulator and mixer designed for efficient and homogenous wet granulation of powders. It features a bottom drive mechanism and is built using GMP-compliant 316 stainless steel, ensuring robust, clean processing suitable for pharmaceutical and chemical applications. The granulator supports flexible processing with user-defined settings for mixer and chopper blade speeds, allowing for aqueous and solvent processing. An optional jacketed bowl enables precise product temperature control, and the system can also be equipped for vacuum drying for all-in-one processing. Built with ease of access in mind, it allows for straightforward maintenance, calibration, and inspection. Engineered scalability allows for processing volumes ranging from 30 liters to 1800 liters, accommodating various production needs. The Smart-Safe™ containment and EcoClean™ technology enhance safety and simplify cleaning, making it a versatile solution for granulation suites.

High shear granulation mixing system

Lyophilization

Vacuum

In pharmaceutical and chemical industries, achieving uniform and dense granules from powder mixtures is crucial for product consistency. Traditional mixing methods may result in uneven granulation and poor end-product quality, necessitating an advanced approach in wet granulation processes.
<h2>Ensures uniform and efficient wet granulation</h2>
The GMX-25 GRANUMEIST® by Freund is a high shear granulator designed for efficient and homogeneous wet granulation of powders. Its top-drive design facilitates easy cleaning and maintenance, rapid processing times, and enhanced user safety. Equipped with user-defined settings for mixer and chopper blade speeds, and an integrated peristaltic pump for precise solution addition, it offers processing flexibility for aqueous and solvent processing. An optional jacketed bowl allows for precise product temperature control. The removable bowl and vertical shaft chopper improve granulation and ease of maintenance. The system is portable, with electrical and compressed air connections mounted on casters for maneuverability. The color touchscreen control system supports both automatic and manual modes, offering validatable process control and USB data collection.

High shear wet granulation system

In research labs and small-scale production, achieving uniform, dense granulation from powdered materials can be challenging. Common issues include inconsistent hardness, irregular density, and excess fines that impact the final product's quality.
<h2>Produce consistent compacted sheets</h2>
The GFC-LAB Micro GRANUFORCE™ by Freund is a versatile benchtop system designed for dry granulation and densification of powdered materials. It uses a cantilevered roll design and vertical tapered feed screw system to produce uniform sheets with consistent hardness and increased density. The unit's compact size and roll gap control via hydraulic pressure allow precise adjustments, making it suitable for small processing volumes of 5g to 1kg/hr. The optional granulating mill further enhances particle size reduction. Built for ease of use and cleaning, the system supports efficient process development and can scale up to production models. This roller compactor is ideal for applications in pharmaceuticals, chemicals, and other industries requiring precise powder processing.

Benchtop roller compacting system

In industrial manufacturing processes, achieving uniform granulation can be challenging due to varying particle sizes and moisture content. Consistent granulation is critical for efficient downstream processing and product quality.
<h2>Facilitates uniform and controlled granulation</h2>
The FC-M FLO-COATER® by Freund is a multipurpose fluid bed system designed for both pilot and production-scale granulation. The system offers flexible configurations with capacities ranging from 20L to 1900L, making it suitable for various production volumes. It utilizes top spray granulation and bottom spray for both solution and powder coatings. The patented Wurster Accelerator System significantly reduces process times, while the GRANUREX® rotor technology enhances solution/suspension coating, spherical granulation, and polymer/powder layering. Additionally, the system includes EcoClean™ technology, which features high-pressure, low-volume cleaning systems and removable cartridge filters with single-point cleaning connections. Optional inline PAT monitoring provides real-time moisture and drying analysis to ensure optimal processing conditions. The FC-M FLO-COATER® is designed to meet the rigorous requirements of industries such as pharmaceuticals, food processing, and chemicals.

Fluid bed granulator for industrial granulation

Analysis

Industrial measurement equipment is used as a crucial step before products leave the production line. These measuring instruments check for correct dosage and standards. Equipment for measurement and control employs a wide range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized measuring tools allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

In many R&D labs, there's a need for versatile systems that can handle various granulation and coating processes efficiently. However, traditional systems can be cumbersome to maintain and switch between different processes, leading to increased downtime and associated costs.
<h2>Flexible granulation and efficient coating</h2>
The FC-LAB 3XL FLO-COATER® by Freund is a laboratory-scale fluid bed system designed to address the diverse needs of process development. This system stands out due to its combination product container/Wurster processing insert and integrated solution pump, eliminating the need for additional costly components. It supports drying, top spray, and bottom spray capabilities, as well as optional GRANUREX® rotor insertion. The design allows for quick changeovers and easy cleaning, enhancing operational efficiency. Featuring a patented Wurster Accelerator System, it reduces process time significantly. With portable and self-contained design, the FC-LAB 3XL FLO-COATER® offers flexibility for aqueous and solvent processing. Optional features include inline PAT monitoring for real-time moisture and drying analysis, and a Smart-Safe™ containment system to maintain safety standards. It complies with CE, ATEX, UL, NFPA, and CSA standards, making it viable for various lab applications.

Laboratory fluid bed granulator and coater

In pharmaceutical and chemical research, developing processes for granulation and coating requires precise control and flexibility. Researchers need equipment that can handle multiple processes while ensuring easy cleaning and quick changeover to maximize efficiency during development stages.
<h2>Supports granulation, coating, and drying processes</h2>
The FC-LAB 1 FLO-COATER® by Freund is a laboratory scale fluid bed system designed for versatile process development. It supports drying, top spray, and bottom spray capabilities, with an optional GRANUREX® rotor insert for enhanced granulation and coating functions. The system features a combination product container and Wurster processing insert with an integrated solution pump, eliminating the need for additional costly add-ons. The portable and self-contained design ensures easy integration and removal with simple electrical and compressed air connections. An intuitive color touchscreen control system facilitates both automatic and manual operation, with validatable process controls such as inlet airflow and temperature control. With a quick-changeover design, no tools are required for process changeover, making it highly efficient for research environments. The unit conforms to CE, ATEX, UL, NFPA, and CSA standards, ensuring it meets various international safety and performance criteria.

Laboratory scale fluid bed system for granulation and coating

When dealing with the challenge of converting raw feedstocks like wood chips, corn stover, and bamboo into uniform particles, traditional equipment can often require pre-drying and consume high amounts of energy. This process can be inefficient and costly, especially for materials with varying moisture contents.
<h2>Achieve uniform particle size efficiently</h2>
The M24M Series Crumbler® from Forest Concepts is a medium-scale rotary shear designed to handle a wide range of materials including wood chips, corn stover, switchgrass, bamboo, sage, hemp, and agave. Capable of processing up to 2 wet tons (1 dry ton) per hour and 4,000 wet tons (2,000 dry tons) per year, it produces highly uniform particles that enhance conversion efficiencies. Unlike traditional systems, it operates efficiently without requiring pre-drying of high and low moisture feedstocks. Featuring options for 20hp or 30hp energy consumption and customizable PLC controls, this compact rotary shear fits seamlessly into various system configurations, including single unit, stacked, or sequential setups. The modular design accommodates different cutter-width processing heads, allowing for precise tailoring of particle sizes. With a small footprint of 4.8’ x 4.3’, smooth and quiet operation, and standard 460VAC 3ph power, it offers robust performance with low energy requirements.

Rotary shear for wood chips and biomass processing

In pharmaceutical manufacturing, achieving uniform particle size and consistent mixture quality is essential. Traditional mixing processes often struggle with issues like uneven granule size and excessive heat generation, which can compromise the product’s quality.
<h2>Ensures uniform mixing and granulation</h2>
The High Shear Mixer Granulator by Fabtech is designed to address these challenges with its ergonomic and compact design. It facilitates both dry mixing and wet granulation processes, ensuring homogeneous mixing and even binder distribution. The four-blade impeller design provides efficient dry mixing, while the rapidly moving chopper blades break down oversized agglomerates and distribute the binder uniformly. Constructed in SS 316, the mixer includes features such as a wet co-mill at discharge for uniform drying, a binder addition port with sprinkle nozzle, and a pneumatically operated top lid and discharge port. The system is GMP and 21 CFR Part 11 compliant, making it suitable for various scales of pharmaceutical production, from lab to commercial models.

High shear mixer granulator for efficient wet granulation

In the pharmaceutical and chemical industries, efficient granulation and coating processes are essential for producing high-quality products. Challenges often include long process times and complex material handling requirements that demand precise control and flexibility.
<h2>Granulate and coat in a single vessel</h2>
The Fluid Bed Processor by Fabtech is designed to handle multiple processes like granulation and coating within a single vessel. This combined approach reduces material handling and process times compared to other wet granulation processes. The top spray method in the fluid bed system produces granules with a porous structure that enhances wettability. This system is cGMP and 21 CFR Part 11 compliant and constructed with SS 316/SS316L for lab, pilot, and commercial production models. The contact parts feature a mirror finish, while the non-contact parts have a matt finish. Additional features include a pneumatically controlled damper for accurate air monitoring, a 3-stage filtration system, and a spray gun for precise control. It also supports high containment isolation systems to ensure operator safety.

Fluid bed processor for granulation and coating

Factories producing pharmaceutical tablets or capsules often face challenges with contamination and product loss. To address these issues, ensuring a fully contained granulation process is critical for maintaining quality and safety standards.
<h2>Achieve dust-free, efficient granulation</h2>
The Closed Loop Granulator by Fabtech is a comprehensive granulation system designed to enhance productivity and safety in pharmaceutical manufacturing. This system incorporates a Rapid Mixer Granulator, Fluid Bed Equipment, a Vacuum Transfer System, a Dry Co mill, and a Blender, all connected through stainless steel (SS 316L) braided flexible pipelines. These connections ensure completely closed and contained product transfer, reducing contamination risks. The granulation line is fully automated, minimizing human intervention and improving yield rates. Constructed with cGMP and 21 CFR Part 11 compliance, the system supports batch sizes up to 300 kgs and is available in laboratory, pilot, and commercial production models. Product contact parts are mirror-finished for easy cleaning, while non-contact parts are matt-finished for durability.

Closed loop granulator for pharmaceutical production

In pharmaceutical production, creating uniform wet granules is essential for ensuring homogenous end products. The process requires reliable granulation equipment that can handle various material types and produce granules in different sizes as needed.
<h2>Produce consistent wet granules efficiently</h2>
The Wet Granulator FGS II from ERWEKA is designed for the production of wet granules with an oscillating rotor. This granulator can produce granules in varying sizes depending on the employed sieve mesh, making it highly versatile. All parts that come into contact with the product are made of stainless steel, ensuring durability and ease of cleaning. Its working capacity reaches up to 30 kg per hour, depending on the material and sieve mesh width used. The granulator is supplied with two sieves (1.0 mm and 1.6 mm MW) as standard, with additional mesh sizes available to meet specific needs, ranging from 0.315 mm to 3.15 mm. An integrated emergency stop feature enhances operator safety.

Wet granulator for pharmaceutical applications

In industries like food, pharmaceuticals, and chemicals, consistent and uniform mixing is crucial. Often, mixing tasks involve handling difficult mixtures or liquids, which can be challenging without the right equipment. Ensuring optimum homogeneity while maintaining ease of operation and cleaning is essential for achieving reliable results.
<h2>Combines mixing and granulating efficiently</h2>
The V10 - V100 by Diosna is a universal mixer granulator available in five different versions with capacities ranging from 11.5 to 180 liters. Designed to solve a wide range of mixing challenges, it delivers optimum homogeneity for solid and liquid mixtures. Its compact cylindrical-conical shape ensures easy placement, and the robust construction is built to last. The powerful chopper provides uniform and reproducible particle sizes, making it suitable for difficult mixtures. Industries such as food (e.g., spice mixers and ready-made soups), pharmaceuticals (e.g., powder mixtures), chemicals (e.g., powder coatings), and cosmetics (e.g., face powder and eye shadow) will find this mixer granulator versatile and reliable. Equipped with push buttons and timers in its control cabinet, the V10 - V100 ensures straightforward operation and simplified cleaning processes.

Versatile entry-level mixer granulator

In pharmaceutical production, ensuring uniform granulation and mixing on a large scale is crucial. Traditional methods often face challenges like inconsistent granule size and labor-intensive cleaning processes, which can hinder efficiency and compliance with regulatory standards.
<h2>Ensures uniform granulation and efficient mixing</h2>
The P 250-1250 by Diosna is a high-performance pharmaceutical mixer granulator designed for large-scale production. It features an automated cleaning system that simplifies maintenance and ensures hygiene. The equipment's advanced mixing tool and bowl design deliver consistent and high-quality granules. It integrates seamlessly with fluid bed processors, optimizing workflows. The stable operating platform offers easy access to the mixer bowl, enhancing operational convenience. Additionally, the integrated industrial PC enables precise batch data logging and meets 21 CFR part 11 requirements, ensuring regulatory compliance. With options like the DIOSNA-Toollift for shaft seal inspection, it minimizes downtime and maximizes efficiency in pharmaceutical manufacturing.

Pharmaceutical high-shear mixer granulator

For pharmaceutical production start-ups, achieving consistent product quality and process reproducibility is crucial. Challenges include maintaining homogeneous mixtures and achieving optimal granulation with smaller batch sizes.
<h2>Efficiently mix and granulate small batches</h2>
The P 100 is a high-shear mixer granulator designed by DIOSNA to support production start-ups in the pharmaceutical industry. This granulator provides excellent blending and granulation, ensuring reproducible processes for batch sizes ranging from 30% to 90% of the total volume. It features a compact design that is pressure shock resistant and complies with ATEX requirements for inerting applications. The P 100's swing-open spout housing allows for easy cleaning, and its effective mixing tools and optimized vessel geometry guarantee the best product flow. Flexible installation options enable placement in the technical zone or the production hall, adapting to your spatial constraints.

High-shear mixer granulator for pharmaceutical production start-up

In pharmaceutical manufacturing, ensuring high product yield while maintaining stringent safety standards is critical. Managing the granulation process efficiently can prevent product loss and optimize overall production performance.
<h2>Optimize granulation with minimal product loss</h2>
The CGS compact granulation system from Diosna is designed to enhance your production processes with precision. Featuring geometrically optimized lines between the mixer and dryer, this system reduces product-contacting surfaces, thereby maximizing yield. It ensures safe operation with integrated explosion protection per ATEX standards, accommodating solvent applications. Additionally, the system is designed for easy maintenance, with all components accessible via an operating platform. The CGS system supports batch production ranging from 25 to 600 kg and offers 21 CFR Part 11-compliant software for data recording and documentation, controlled through two operator terminals. The granulation line adheres to GAMP 5 standards and integrates PAT concepts to meet quality control requirements.

Pharmaceutical granulation line

In pharmaceutical manufacturing, ensuring consistent product quality and compliance with stringent regulations is crucial. Achieving optimal granulation can be challenging, especially when transitioning from clinical samples to full-scale production batches and meeting regulatory standards like 21 CFR Part 11.
<h2>Handles mixing, granulation, and drying processes</h2>
The CCS granulation line by Diosna integrates a mixer-granulator with a fluid bed processor to streamline wet granulation and subsequent drying. The system features quick change of material containers without tools, allowing efficient batch processing. Its through-the-wall setup ensures strict separation between production and technical areas, enhancing contamination control. Automated processes backed by 21 CFR Part 11 compliant PC control and remote maintenance bolster operational efficiency. Pressure-shock resistant up to 12 bar, the fluidized bed unit meets regulatory and safety requirements, including ATEX standards. With user-friendly terminals and customizable container sizes, the CCS line is suitable for adapting to diverse production needs in the pharmaceutical industry.

Granulation line for pharmaceutical manufacturing

In laboratory research, the precision and flexibility of granulation and coating processes are critical. Variability in batch sizes and process parameters can pose challenges, necessitating adaptable and precise equipment to meet diverse research needs.
<h2>Granulate, dry, and coat efficiently</h2>
The Minilab RC by Diosna is a versatile laboratory unit designed for granulating, drying, and coating in one system. It features the Rapid Change system, which allows seamless transitions between its fluid bed module for drying and spray granulation, and its drum coater for powder, pellet, or tablet coating. The unit offers an intuitive operation via a full graphic display and easy cleaning with tool-free disassembly. Glass components ensure excellent process monitoring, and its flexible batch sizes range from 0.2 to 3.2 kg for the fluid-bed module and 0.5 to 2.7 kg for the drum coater. Additionally, its compact design makes it ideal for benchtop use, supporting rapid product and process development. Extra features such as a microkit, different fluidized bed containers, and exchangeable drums enhance its adaptability.

Laboratory granulator and coating system

When you're transitioning from laboratory to large-scale production, optimizing processes like granulating, drying, and coating is crucial. Space limitations in pilot plants or production halls often complicate this scale-up, requiring solutions that offer flexibility and efficient use of available space.
<h2>Granulates, dries, and coats with scalable flexibility</h2>
The CAP 10-80 RC by Diosna is a comprehensive fluidised bed processor designed for pilot-scale operations, ideal for producing granulates, powders, and coated tablets. This versatile system supports top, bottom, or tangential spray technologies, enabling fluid bed granulation, drying, and Wurster coating to be performed efficiently. Its low installation height and swiveling centre section ensure easy integration into spaces with low ceilings. The system features the Rapid Change principle, allowing for quick and flexible changes of product bowls, covering diverse batch sizes from 5 to 36 kg. Additionally, its design includes pressure shock resistance and inflatable seals for safety. The apparatus streamlines automated processes and recipe storage, enhancing process optimization. Crucially, the filter housing is located at body height and can be swiveled for convenient access to filter elements, ensuring minimal maintenance disruptions. Diosna’s CAP 10-80 RC is fully qualified for production-scale use, adhering to GMP standards with CIP and WIP cleaning concepts, making it an excellent choice for industries such as pharma solids and fine chemicals.

Fluid bed processor for granulating, drying, and coating in pilot scale

When handling chemical or toxic substances, accurate and safe filling of containers or drums is crucial to meet strict safety regulations. Ensuring dust emission control and handling a variety of container sizes are significant challenges faced in these processes.
<h2>Fill drums and containers reliably and safely</h2>
The IBC/Drum Filling System by Dinnissen addresses the complexities involved in filling drums and containers with chemical or toxic substances. Designed for intensive use under harsh conditions, this system complies with European REACH regulation for chemical safety. It features a modular design and customizable components. The filling process can include supply of empty drums, dust extraction to prevent fine dust release, and vibration for compacting dust within the containers. The filling station also supports various container sizes with easy-to-operate filling adapters and optional height adjustments. Additionally, it can be equipped with an Easy-to-clean Feeder Valve for accurate dosing and a turntable for minimizing manual handling. Suitable for use in industries such as food, pharma, pet food, feed, and chemicals, this system ensures high efficiency and compliance with strict dust emission standards.

Ibc and drum filling system for chemical substances

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

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

In the research and development of pharmaceutical and chemical formulations, precise control over mixing, extruding, and spheronization processes is critical. Small batch sizes and customizable parameters are often needed to optimize formulations and reduce waste.
<h2>Mix, granulate, extrude, and spheronize efficiently</h2>
The Caleva Multi Lab, provided by Caleva Process Solutions, is an all-in-one lab scale tool designed for formulation development. The device allows for mixing, granulating, extruding, and spheronizing in batch sizes from 10 grams to 50 grams, making it suitable for small-scale R&D projects. The system includes a standard and high-density die at no extra cost, enabling the exploration of different extrusion parameters. It also has interchangeable mixing bowls (275ml and 71ml) and blades, including a Sigma blade and bowl system for high-viscosity materials. The compact design minimizes bench space, fitting three distinct processes into a single, small footprint machine. This equipment is particularly valuable for pharmaceutical, chemical, and catalyst production, where precise control over pellet size, density, and surface area is essential for successful formulation.

Lab scale mixer, extruder & spheronizer for r&d formulation

When working in a laboratory setting, you often need to deagglomerate, blend, or granulate small batch samples. Handling materials like fine powders, pastes, and slurries efficiently can be challenging without the right equipment, potentially slowing down your development processes.
<h2>Deagglomerates fine powders and mixes liquids</h2>
The Caleva Mixer Granulator Blender (MGB) is a versatile laboratory tool designed for mixing, blending, and granulating small batch samples efficiently. This component of the Caleva Multi Lab stands out for its ability to handle a wide range of materials, such as fine powders, pastes, and slurries with batch sizes from 10 g to 50 g or liquid samples ranging from 20 ml to 170 ml. Equipped with different mixing bowl and blade sets, including water jacketed bowls and bowl inserts, the MGB enables tailored batch processing based on product properties. Ideal for industries such as pharmaceuticals, food, cosmetics, and chemical processing, the MGB allows quick changes between trials, speeding up research and development with less product use. Caleva Process Solutions tests confirm the MGB's efficacy in handling diverse materials from inorganic chemicals to crystalline salts and room-temperature wax blending.

Small batch mixer granulator blender

Developing new polymer formulations or testing small amounts of high-value materials often requires precise control over the compounding process. Challenges include ensuring optimal mixing, minimizing material loss, and speeding up the cleaning process for frequent formulation changes.
<h2>Enables efficient small-scale compounding</h2>
The Mini-Compounder KETSE 12/36 from Brabender is a highly adaptable and easy-to-use tool designed for laboratory-scale polymer processing. It features a horizontally divided barrel that can be tilted open for easy visual assessment of processing steps, along with quick cleaning capabilities. The barrel length is 36 D, with metering or venting ports available at 6 D, 12 D, and 26 D lengths. Additional side feeders can be installed at a 14 D processing length, enhancing its versatility. This mini-compounder is ideal for a range of applications, providing reliable results with small sample sizes, which makes it a valuable asset in research and development settings.

Mini-compounder for laboratory polymer processing

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

In pharmaceutical production, achieving uniform granule size is essential for consistent product quality and enhancing bioavailability. Traditional batch granulation methods often result in variability and inefficiency, making it challenging to maintain high standards in large-scale operations.
<h2>Ensures uniform granule size in continuous production</h2>
The Continuous Wet Granulation Equipment by Austar provides a reliable solution for producing uniform granules in a consistent, efficient manner. This equipment is specifically designed for the pharmaceutical industry, offering a seamless integration into existing production lines. Utilizing advanced granulation techniques, the system ensures that each granule meets stringent quality standards, significantly reducing production variability. The continuous process also enhances efficiency, allowing for higher throughput and reducing downtime associated with batch processing. Ideal for large-scale manufacturing, it supports the production of tablets and similar oral dosage forms by delivering precise, repeatable results. Additionally, the system is designed for easy cleaning and maintenance, ensuring compliance with stringent regulatory requirements.

Continuous wet granulation equipment

In pharmaceutical manufacturing, achieving consistent granule size and composition is crucial for the production of solid dosage forms like tablets. Traditional batch granulation methods can be time-consuming and labor-intensive, requiring advanced solutions for continuous operation and precise control.
<h2>Provides consistent granule size for pharmaceuticals</h2>
The continuous wet granulation equipment by Austar, developed in partnership with NEUHAUS NEOTEC, offers a comprehensive solution for the pharmaceutical industry. The system integrates auto loss-in-weight feeding, mixing, granulating, drying, tableting, and tablet coating, ensuring seamless operation. It supports top-spray granulating and bottom-spray pellet coating using a horizontal fluid bed processor. Capable of handling scales from pilot (20 kg/h) to commercial production (>2000 kg/h), it features an automatic control system compliant with data integrity requirements from EMA and FDA. The production line holds ATEX explosion-proof certification from the EU, incorporating PAT technology for real-time process monitoring and feedback.

In pharmaceutical manufacturing, achieving consistent granule size and composition is critical for drug efficacy and quality. Traditional granulation techniques often struggle with inefficiencies and contamination risks, necessitating advanced solutions to enhance productivity and ensure safety.
<h2>Achieve consistent granulation and improve safety standards</h2>
The wet granulating equipment by Austar combines Process Analytical Technology (PAT), containment technology, and powder handling expertise to optimize the wet granulating and pellet coating processes. This technology ensures precise granule sizes and consistent compositions by leveraging innovative process designs, fluid technologies, and rigorous automatic control systems. For high toxic or active pharmaceutical ingredient (API) productions, the system includes high containment solutions compliant with OEB3 to OEB5 standards, developed in collaboration with European EHS experts. The equipment also integrates advanced batch management, electronic records and signatures, and audit trails to meet stringent data integrity requirements by FDA, EMA, and WHO. Designed in accordance with GAMP5 guidelines, the automatic control system is supported by high-quality, standardized validation documents. The system comes with robust after-sales support, ensuring timely and professional responses. Applications span a wide range of pharmaceutical manufacturing processes, particularly those requiring high precision and contamination control.

Wet granulating equipment for pharmaceutical industry

In industries like food, pharmaceuticals, and chemicals, achieving uniform particle size and structure in bulk materials is crucial. This is particularly challenging when working with dry powders, slurries, and highly viscous products, which require precise granulation and mixing.
<h2>Uniform granulation of bulk materials</h2>
The Continuous Granulator / Ring-layer mix-pelletizer RMG by Amixon is designed to meet the demands of granulation in industries dealing with powdery goods. This equipment employs mixing tools such as tillers or paddles that cover the entire cylindrical mixing chamber, ensuring thorough mixing and deagglomeration. The device allows dry powders to be moistened and can handle slurries and highly viscous materials effectively, creating uniform agglomerates. The process is divided into several treatment zones, including intensive mixing, wetting, and agglomeration by build-up granulation, followed by continuous discharge. The robust construction features thick-walled sheet metal and is machined for a particularly round chamber. Large inspection doors with OmgaSeal technology facilitate cleaning and inspection. Additional features include wear-resistant designs, double jackets for temperature control, and washing-in-place equipment. Amixon adheres to stringent hygiene standards such as EHEDG, 3-A, FDA, and GMP, making it suitable for high-demand environments.

Continuous granulator for powdery goods

Pharmaceutical production often demands highly controlled granulation processes to ensure product consistency and quality. Traditional methods may not meet stringent industry standards for efficiency and containment, leading to potential issues in product uniformity and safety.
<h2>Compacts and granulates pharmaceutical products efficiently</h2>
The WP 150 Pharmaceutical Roller Compactor by Alexanderwerk is designed to meet the highest standards of the pharmaceutical industry. It features a vertical roller arrangement that enhances feed flow control, reducing fine material in the final product. The patented Combi-Vent-Feeder® system ensures uniform feeding by allowing air to escape, which avoids feed disturbances. The Diagonal-Design® single-stage granulator increases throughput by up to 100% and improves screen efficiency. The WP 150 is capable of producing up to 250 kg/h of granulated product, making it suitable for high-volume production environments. With an advanced interface for comprehensive control over roller gap and compaction pressure, it offers precise control options, ensuring consistent quality. Key specifications include a roller width of 50 mm, diameter of 150 mm, and maximal pressure force of 20 kN/cm. The equipment also has built-in features for pre-crushing and individualized compaction, optimizing the process further.

Pharmaceutical roller compactor for granulation

In pharmaceutical and chemical production, raw materials often need to be grated or shredded to achieve a defined particle size for further processing. This is crucial for maintaining consistency and quality in the final product.
<h2>Achieve precise particle size reduction</h2>
The PGS Series by Alexanderwerk Inc. is engineered for grating, shredding, crushing, and deagglomerating solid, dry, or slightly moist substances. Designed to meet pharmaceutical, chemical, and industrial standards, it includes features such as a universal drive motor with a quick release coupling for easy attachment changes, including the RFG 150 DA rotor fine granulator. It can process up to 10,000 kg/h, depending on the material and cylinder type. The cylinders are available with various bore sizes to produce different granule geometries. The mobile design allows for flexible positioning and easy maintenance, making it a versatile choice for various industries.

Industrial grater and shredder for pharmaceutical and chemical applications

When producing pharmaceuticals or nutraceuticals, achieving content uniformity and narrow particle-size distribution during wet granulation is crucial. Common challenges include ensuring consistent material processing and maintaining operator safety in high-pressure environments.
<h2>Ensures uniform granulation with enhanced safety</h2>
The QUEST HSM II by ACG World is an advanced high-shear granulator designed for precise wet granulation. Equipped with ACG X•ONE command process control, it ensures faster processing and uniform granule size. The system features the unique MOST™ (Maximum Operator Safety Technology) concept, making it highly safe and compliant with cGMP standards. It offers interchangeable bowls of 2, 5, and 10 liters, facilitating flexible batch sizes. The granulator's Z-shaped impeller blades and laser-cut multi-blade chopper ensure optimal material flow and uniform binder distribution, minimizing lumps and 'dead zones' during processing. This system is mobile and plug-and-play, allowing easy use in various lab settings.

High-shear granulator for wet granulation

In the pharmaceutical and nutraceutical industries, achieving precise content uniformity in dry mix formulations is critical for product efficacy. This need arises especially during the production of small batches where consistent particle-size distribution is essential.
<h2>Ensures uniform mixing and faster processing</h2>
The HSM 300 X·ONE by ACG World is an advanced high-shear mixer granulator designed for small production batches. It features a unique product bowl geometry that maintains a roping flow regime, ensuring uniform mixing and faster process stabilization. The system includes a Z-shaped impeller and a multi-blade chopper, which produce superior centrifugal force, minimizing dead zones and achieving optimal particle-size distribution. Equipped with ACG's exclusive X·ONE command process control system, it allows secure and intuitive monitoring and control. Notably, the HSM 300 X·ONE integrates the MOST™ (Maximum Operator Safety Technology) concept, featuring a 12-bar pressure shock-resistant system compliant with ATEX (Directive 2014/34/EU). This makes it ideal for safe operations, ensuring quick resumption of production post any pressure-shock event. Multiple systems for charging, discharging, and wash-in-place (WIP) facilitate efficient product handling and easy cleaning, resulting in higher yield.

High-shear mixer granulator for small batches

In the production of pharmaceuticals and nutraceuticals, achieving consistent particle size distribution and content uniformity in the dry mix is crucial. Traditional mixing techniques may not provide the precision or efficiency needed, leading to variability in product quality.
<h2>Ensures uniform particle-size distribution and content uniformity</h2>
The HSM 2000 X·ONE, offered by ACG World, is an advanced high-shear mixer granulator designed for large production batches. This equipment is equipped with the ACG X·ONE command process control system and features unique MOST™ (Maximum Operator Safety Technology). The system ensures faster processing times and narrow particle-size distribution, making it suitable for applications such as wet granulation and mixing. The HSM 2000 X·ONE can be integrated into a granulation train or used as a standalone unit. Its Z-shaped impeller and multi-blade chopper create superior centrifugal force, significantly reducing dead zones and achieving uniform binder distribution for optimal particle size. Notably, the equipment offers a 12-bar pressure shock-resistant system compliant with ATEX (Directive 2014/34/EU) and certified by FSA in Germany. ACG's exclusive X·ONE command process control system assures intuitive and secure monitoring compliant with ATEX, GAMP 5, and 21 CFR Part 11 standards. The system supports efficient product handling and easy cleaning with multiple charging, discharging, and wash-in-place (WIP) systems.

High-shear mixer granulator for pharma and nutraceuticals

In pharmaceutical manufacturing, achieving efficient and dust-free granulation processes is essential for producing high-quality products. Traditional approaches often fall short in terms of efficiency, safety, and space utilization, posing significant challenges for manufacturers.
<h2>Combines high-shear mixing and fluid-bed systems</h2>
The GT series from ACG World is an integrated granulation system designed to optimize manufacturing efficiency while ensuring safe, single-handed operation. The system combines an advanced high-shear mixer (HSM) and fluid-bed (FBE/FBC) system, which are designed in Germany. It achieves a highly efficient, dust-free wet granulation process within a cost-effective, closed-loop design. The contained product handling is supported by a vacuum charging system that ensures closed-loop transfer for smooth material flow and minimum product leftover. The compact design reduces floorspace requirements by around 50%, and the through-the-wall construction allows clear separation between processing and technical areas, ensuring easier maintenance, cleaning, operation, and GMP compliance. Additionally, multiple systems for charging, discharging, and WIP (wash-in-place) minimize dust generation and product exposure, making GMP compliance easier. The equipment can be customized to a wide range of product and process requirements.

Integrated granulation train for pharmaceutical processes

Industrial washing systems are used to clean and disinfect a variety of items in research and manufacturing facilities. Industrial washers use solvents and cleaning agents with mechanical action to remove deposits and residues from stainless steel machinery components, empty containers, and other soiled surfaces. The selection of an industrial or commercial washer depends on the type of items and surfaces to be cleaned, the type of deposits/residue that is typically present, whether drying is required after rinsing and the level of sterilization necessary. Manufacturers will have cleaning specifications and as a result, require washers to be engineered to meet these specs.

Washing

When developing and scaling pharmaceutical formulations, finding an efficient and safe method for granulation and drying is crucial. Top-spray granulation and wet-mass drying processes require equipment that ensures consistent results while maintaining operational safety standards.
<h2>Enhance granulation and drying safety</h2>
The FBE 1800 X•ONE from ACG World is designed to provide advanced fluid bed granulation and drying for batches up to 1,800 liters. Manufactured in their Design Centre in Mülheim, Germany, it offers exceptional performance and operational safety. It features a 12-bar pressure-shock-resistant system, equipped with the MOST™ concept, approved by FSA from Germany, ensuring no mechanical deformation occurs during pressure shocks. The system supports applications such as top-spray granulation, wet-mass drying, and hot-melt granulation. With ATEX (Directive 2014/34/EU) compliance, the FBE 1800 X•ONE integrates unique C-flanges to prevent the external release of explosion pressure, X•ONE inflatable seals for low-pressure safety, and QASV (Quick Action Stop Valves) that contain explosions within 20 milliseconds. Additionally, the exclusive X•ONE command process control system facilitates secure and intuitive monitoring, adhering to GAMP 5 and 21 CFR Part 11 standards. The fluid bed granulator is customizable with charging, discharging, and WIP (wash-in-place) systems, available in standalone or granulation-train configurations suitable for the pharmaceutical industry.

Fluid bed granulator for pharmaceutical applications

In pharmaceutical and nutraceutical production, processing large batches often demands efficient drying and granulation techniques to ensure product quality and consistency. Limitations in traditional methods can lead to prolonged processing times and incomplete granulation, requiring advanced solutions tailored specifically for these industries.
<h2>Dry and granulate batches up to 1,300 liters</h2>
The FBE 1300 is a high-performing fluid-bed system from ACG World, designed for both drying and top-spray granulation. It is ideal for pharmaceutical and nutraceutical production, accommodating batches up to 1,300 liters. The system ensures operator and product safety with a precisely calculated and tested vent for handling pressure shocks. A state-of-the-art filter bag shaking system maximizes filtration area while minimizing compressed air consumption, making it more efficient and easier to maintain. Additionally, the 21 CFR part 11-compliant PC control system provides a regulatory-compliant, audit-friendly environment. The equipment is flexible, available in customized charging, discharging, and wash-in-place (WIP) systems, suitable for standalone or granulation-train configurations. The working volume ranges from 335 to 1,288 liters, depending on the bulk density of the material.

Fluid-bed drying and granulation system

In pharmaceutical manufacturing, ensuring uniform particle size in granulation can be challenging when working with batch processes. Processing efficiency and operational safety are often major concerns, requiring reliable technology to optimize granulation and drying.
<h2>Granulate and dry batches up to 125 liters</h2>
The FBE 125 X•ONE from ACG World is an advanced fluid-bed system designed for top-spray granulation and drying. Developed at the company’s Design Centre in Mülheim, Germany, it offers superior performance and operational safety. With a working volume range from 33 to 168 liters, it is suitable for handling batches up to 125 liters. The system includes a 12-bar pressure-shock-resistant design featuring the MOST™ concept, approved by FSA from Germany and compliant with ATEX (Directive 2014/34/EU). The unique C-flanges prevent explosion pressure transfer beyond the unit, and the X•ONE inflatable seals ensure safety at pressures as low as 4.5 bar. The integrated QASV (Quick Action Stop Valves) contain explosions within 20 milliseconds. Additionally, the X•ONE command process control system provides secure and intuitive monitoring, compliant with GAMP 5 and 21 CFR Part 11 standards. The unit comes with customized charging, discharging, and WIP (wash-in-place) systems for efficient processing and reduced changeover times.

Fluid-bed granulator for top-spray applications

In academic and research settings, handling small batches for granulation, drying, and coating processes requires precise and versatile equipment. The challenge lies in achieving efficient granulation and coating without scaling up to industrial-level machinery.
<h2>Enables versatile granulation and coating operations</h2>
The MINIQUEST F by ACG World is a compact, tabletop system designed for handling batch sizes as small as 50g. It utilizes top-spray granulation and Wurster coating technology in a single unit. The system features a Düsen-Schlick nozzle from Germany, facilitating drying, granulation, and coating processes efficiently. Its integrated peristaltic pump minimizes the system footprint, making it ideal for academic use. An innovative tower assembly allows for easy operation, inspection, and cleaning. The venturi-based fluidisation system eliminates the need for an electrically powered blower, simplifying installation and reducing costs. A 5μ sock filter ensures a cleaner working environment by preventing dust escape. Ideal for research settings, this system supports multiple granulation techniques including top-spray, tangential spray, and hot-melt granulation.

Tabletop granulation system for small batches

In the pharmaceutical industry, dealing with varied processes such as drying, granulation, and coating often requires multiple machines, adding complexity and inefficiency to production lines. This creates a need for versatile, robust equipment that can handle multiple processes within a single system.
<h2>Integrated drying, granulation, and coating</h2>
The FBC 1800 X•ONE by ACG World is a versatile fluid bed combo designed to handle drying, top-spray granulation, and Wurster coating for batches up to 1800 liters. The 12-bar pressure shock-resistant system incorporates the MOST™ concept, ensuring supreme operator safety and compliance with ATEX (Directive 2014/34/EU). Unique features such as C-flanges prevent explosion pressure transfer, while QASV ensures containment of explosions within 20 milliseconds. The system also offers customizable charging, discharging, and WIP (wash-in-place) configurations to enhance efficiency and safety during granulation and pellet processing. The exclusive X•ONE command process control system allows intuitive and secure monitoring, compliant with GAMP 5 and 21 CFR Part 11. With components developed in collaboration with Düsen-Schlick GmbH, this solution ensures enhanced productivity and simplified operation and cleaning.

Fluid bed combo for granulation and coating

In pharmaceutical manufacturing, achieving precise granulation and coating of powders while ensuring operator safety is critical. Challenges include controlling dust, preventing cross-contamination, and ensuring uniform coating of particles.
<h2>Combines drying, granulation, and coating processes</h2>
The FBC 125 X•ONE by ACG World is a versatile fluid bed combo designed for diverse applications such as drying, top-spray granulation, and Wurster coating, capable of handling batches up to 125 liters. This system is equipped with the MOST™ (Maximum Operator Safety Technology) concept, approved by the FSA and compliant with ATEX Directive 2014/34/EU, ensuring supreme safety. The innovative C-flanges prevent explosion pressure transfer beyond the system, while the X•ONE inflatable seals provide safety even at low pressures. The system includes Quick Action Stop Valves (QASV) that contain explosions within 20 milliseconds. Furthermore, the exclusive X•ONE command process control system allows intuitive, secure monitoring and control, complying with GAMP 5 and 21 CFR Part 11 standards. Additionally, the machine features patented nozzles developed in collaboration with Düsen-Schlick GmbH, enhancing productivity and simplifying operation and cleaning.

Fluid bed dryer with granulation and coating

The essential objectives of containment systems are personnel protection and preventing the release of toxic or infectious material into the environment. Containment is also used to prevent a product or sample from contamination by the external environment. In the chemical and pharmaceutical industries, containment solutions are used to protect the personnel from the leaking of airborne particles of hazardous substances, as powders or liquids are handled or transferred during processing.

Containment

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

When handling nuts for various processing applications, achieving consistent granule size can be a challenge. Traditional multipurpose machines often crush the product, compromising the quality and consistency of the final granules.
<h2>Precision granulation with custom knife spacings</h2>
The Talon Rotary Blade Granulator by AC Horn Manufacturing is specifically designed to granulate all varieties of nuts into defined, sharp-edged granules with minimal fines production. Unlike other machines that may crush nuts, this granulator provides precise granulation by allowing the operator to choose from eight different knife spacings, ranging from 1/16” to ¼”. The granulator is constructed with stainless steel contact parts, ensuring both efficiency and cleanliness during operation. With a maximum output of 1,200 lbs/hr (545 kg/hr), it offers robust performance for high-capacity needs. This flexibility and precision make it an ideal choice for industries dealing with popcorn, roasted nuts, coated nuts, blanched peanuts, Japanese peanuts, nut butter, and various other snack foods.

Granulator for nut processing

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.

Granulators

Which granulators technology do you need?