Granules via granulation

From Liquid Feeds

Spray Dryer Granulator

Spray Drying Granulation

This is a continuous process where the desired mechanism of particle growth is layering and simultaneous drying of the liquid feed on the surface of the smaller granules and nuclei particles. Liquid is the only feed source. Air temperatures are high to achieve the required drying rates. High density, free flowing granules are produced from solution and slurry feeds. Operational conditions again control granule growth. Granules are produced in the mean size range of 1000 microns to 2000 microns. The process is most suited for inorganic feeds.

From Powder Feeds

High Shear Granulation (continuous)

This process involves mixing the feed materials while these are simultaneously sprayed with liquid. The operation takes place in a slowly rotating drum containing a high speed rotating comminuting bar. Control of the wetting rate and speed of the bar determines granules growth. It is possible to produce granules having a mean size over the range 250 microns to 1500 microns. In the process, much energy is imparted to the particles enabling the formation of compact, high density granules.

High Shear Granulator Fluid bed Granulator

High Shear Granulator (Batch)

Fluid Bed Granulation

A fluid bed granulation process where powder is fed continuously into the granulating chamber and fluidized with warm air. The moistening of the powder is achieved by a top or bottom nozzle spray arrangement. The air distribution plate has directional gill perforations that control particulate flow and gives the necessary residence time of product in the granulator. Granule growth is controlled by the moistening rate, use of binder, fluidizing air temperature and granulation time. It is possible to produce granules with a means size from small (300 microns) to large (1500 microns). Both batch and continuous systems are available.

Special models are available for granulating powders of high dust explosion rating and for granulating under GMP processing standards.

High Shear Granulation (Batch)

A batch wet granulation process incorporating a mixing bowl with base and side mounted impellers (Pharma Matrix™). The shallow wide diameter bowl with a conical upper section guarantees a constant product vortex that reduces any tendency towards product adhering to the bowl walls.

The dry ingredients are fed into the bowl and dry mixed for several minutes followed by introduction under pressure or vacuum of a granulating fluid using an integrated spraying unit. A free flowing granule is produced after a few minutes and then quickly discharged to an in-line fluid bed to dry the granules. Designed for pharmaceutical granulation and batch processing requiring GMP standards.

Granulation can also be combined with microwave vacuum drying in the same unit (Spectrum™). This eliminates potential for operator and environmental contamination during product transfer if a separate dryer is used.