UltimaGral™ High-Shear Mixer Granulators

The basic UltimaGral™ design, first introduced in 1972, is a high shear mixer granulator, in which the processes of dry mixing, wet mixing, and granulation can be executed. The most important features of this basic design are the top-driven mixer and chopper, the removable bowl, and the "through-the-wall" installation of the larger machines.

Ultima™ 25

The basic UltimaGral™ design ranges from 10 L to 1200 L machines.

The range of UltimaGral™ processors extends the concept of the basic UltimaGral™ and allows you to execute the whole cycle of mixing, granulating and drying in a totally contained environment. The UltimaGral™ processors are equipped with a vacuum system to allow drying of the granulate. The Transflo™ system (gas-assisted vacuum drying) can also be provided on UltimaGral™ processors.

Same design of process bowl, mixer and chopper make sure that process and validation wise there is no difference to the Collette Gral. This unique design of process bowl, mixer and chopper makes the UltimaGral™ not only a perfect wet granulator but also an ideal machine for meltgranulation and pelletising.

Stand alone UltimaGral™

Many applications of a high-shear mixer-granulator do not require integration with other equipment. The UltimaGral™ design allows for different ways of setting up a stand-alone machine in a GMP-compliant way:

• The through-the-wall execution: Space saving (reduction of expensive production area), GMP(maintenance interventions outside the production area)
• In the freestanding execution, all mechanical parts are completely covered and sealed, so the machine remains GMP compliant.

Clean in Place (CIP)

Contained processing also requires that the equipment can be cleaned in a contained fashion. The UltimaGral™ can be equipped with a full CIP system that ensures cleaning-in-place of product feed, product filter, bowl and lid and discharge valve.

Even downstream equipment such as a mill can be incorporated in the CIP system.

Process technologies

Apart from executing standard wet granulation processes, the UltimaGral™ can be used for many other applications, such as:

• Melt granulation
• Pelletisation

The UltimaGral™ can produce a wide variety of products:

• Effervescents
• Formulations developed for alternative technologies
• Low binder formulations
• Moisture, heat or light sensitive products
• Vitamins
• Highly potent or toxic drugs

Control Systems

• Basic solution: OP/PLC based (standard)
  • Operator panel as user-friendly interface with the machine
  • Paperless recorder for historical trending
• High end version: PC/PLC based, batch oriented software with process visualisation.
  • Software compliant with ISA S88.01 and NAMUR batch processing standards, quasi-3D process visualization, and unlimited number of recipes.
  • Software designed to be compliant with FDA 21 CFR Part 11.
  • Real-time storage of batch information in a relational database
  • Possible integration into higher level business and enterprise planning systems such as SAP, etc.
  • Video camera for easy visual process monitoring.

The basic UltimaGral™ design is a high-shear mixer-granulator without drying capacities. The features of a basic UltimaGral™ high-shear mixer-granulator are the following:

Standard Features

• Top driven mixer and chopper
• Vertical chopper shaft
• No seals in direct contact with the product
• Free standing machine OR through-the-wall design (only for 75 L or larger)
• Easy to wash-in-place (WIP)
• Built to GMP-standards
• Easy validation
• Full stainless steel construction in process room
• Total containment of the product
• Twin speed chopper and mixer
• Full interlocked guarding
• Operator control panel on the machine
• Easy access for maintenance

Optional Features

• Automation/PC/PLC controls
• Controlled product discharge
• Closed link to wet screening unit
• Liquid addition system
• Explosion proof design
• Fill-O-Matic (vacuum) or gravity loading system
• Automatic end point detection with PROCOLL-software
• Customized machine design
• Jacketed/Insulated bowl
• WIP/CIP
• Heating and cooling units
• Chillers
• Remote visual monitoring
• Mixing arm torque measurement
• Variable speed mixer and chopper motors
• Removable chopper
• Validation documentation and assistance conforming to GAMP