Fluid Bed Dryer / Granulator / Coater

Fluidized Bed Dryer & Granulator and Coater Introduction

FLP multifunction granulating coating machine is composed of a Fluidized dryer - Fluidized granulation - Top spray granulator - bottom spray coating - drying function, etc. It is suitable for the granulation of pharmaceuticals, foodstuffs, health products, and chemical industries. Such as Tea polyphenols granulating, Omeprazole slow-release, Chinese traditional capsule granulating, Coating for cold relief capsule granules, Chinese traditional medicine moisture-proof coating, antibiotic granulating and coating, etc. the centrifugal spheronizer is often connected with the fluid bed dryer coater to coat the pellet.

Fluidized Bed Dryer & Granulator and Coater Drying Funcation

Fluidized Bed Dryer & Granulator and Coater can be use for the wet powder or granules drying.

Bottom Spray Coating

When the hot air passes through the bottom plate of the container and partition column, it will generate the siphoning effect. The pellets will fall down and then be sucked back to the partition column again, while the bottom spray gun will spray the coating binder upward to achieve the coating purpose.

Side Spray Powder Coating/Film Coating

The side spray is better for coating with high firm content. The cores (seeds) are placed on the turntable disc and hot air is blown upward between the turntable disc and the granulation area. The coating solution is sprayed on the rolling cores through the pump and spray gun. The process involves simultaneous coating and drying of the cores, the repeated actions achieve the desired coating thickness or granule size. Powder coating is achieved by charging powder and spray binder at the same time.

Fluidized Bed Dryer Granulator Coater Video

Fluid Bed Spray Granulating Coater Description

Heated and purified air flows into the column by a suction fan, the pellet or powder will be in uniform fluid condition inside the column, use one set of filter bags to prevent the leak of powder, and discharge the evaporated water to get drying purposes. If add one more spray gun can spray the binder or active ingredient downward into the uniform fluid powder, whenever the powder combined in granules will be dried to get the required moisture content.

Top Spray Granulator

The top-spray granulator (the function is same as the fluid bed granulator) agglomerates finer particles into larger, free-flowing granulates in a one-pot process. Ingredients are mixed and preheated by an upward flow of heated air. Granulation occurs by spraying liquid into the fluidized powder. The granules are subsequently dried with heated air. The top-spray granulators can also be used for top-spray coating, layering from liquids, and instantly. Special features include a selection of air distributors and one-pot processing.

Bottom Spray Coating

When the hot air passes through the bottom plate of the container and partition column, it will generate the siphoning effect. The pellets will fall down and then be sucked back to the partition column again, while the bottom spray gun will spray the coating binder upward to achieve the coating purpose.

Drying of Fluid bed spray granulators: Warm air is blown through a perforated distributor to rapidly and gently dry the formulation until the required residual moisture content is reached. Moisture evaporated from the product is exhausted with the drying air. Special features include a selection of air distributors and short processing times.

Inside of tank

Bottom spray

Side Spray

Side Spray Type

Place the cores on the turntable. Hot air is blown upward between the turntable and the granulation area. The air causes the cores to roll, the binder solution is sprayed on the rolling cores through the pump and spray gun, coating and drying simultaneously. If powder coating is required, the fixed volume powder will be sprayed at the same time as let solution coating the powder on the cores to produce a pellet and get coating and drying purposes.

Safety operation

With fluid bed systems, safety always must be considered the highest priority. Due to the static charge of the product, there always remains the risk of an explosive environment within the fluid bed chamber. The safety risk is heightened when solvents are used as the binding solution. Hywell machinery designs fluid beds to an over-pressure and the explosive situation (correctly termed “deflagration”) is contained within the fluid bed chamber. Hywell machinery also offers a vented design, which safely directs the over-pressure situation to an open, safe place.

Fluid Bed Granulation Coater Structures

1. Inlet air system

The inlet air system of the Fluid bed Granulation coater (coating and drying) consists of a Primary filter, Intermediate filter, high-temperature high efficiency filter (H13 ), and heater with accurate temperature control. The inlet airflow, speed, and pressure are variable and controllable. For the heater of Fluid bed granulation, a Fluidized Bed Granulation coater can be a steam radiator or electrical heater.

2. Main Body Structure

The main body structure of the fluidized bed coater consists of a bottom bowl, a movable product bowl with a trolley of granulating, a moveable product bowl with a trolley of coating, a fluidized chamber, and an expansion chamber/filter housing. The bottom bowl, product container, and fluidized chamber are inflatable silicon gaskets sealed with a compress air inspection sensor to assure reliable sealing.

3. Product Filter of Fluid Bed Powder Coating

The double structured bag filter in two pieces (in case request, stainless steel filter available) is an inflatable silicon gasket sealed between the expansion chamber inner surfaces with a compress air inspection sensor to assure the reliable sealing or fix cloth bag on the middle chamber to replace the inflatable the gasket seal.

Fluid Bed Dryer Granulator Coater Specifications

Working Principle of Fluid Bed Dryer/Granulator/Coater

The working principle of the Fluid Bed Dryer/Granulator/Coater revolves around the concept of fluidization. The equipment operates by passing a stream of heated air or gas through a perforated plate or distributor located at the bottom of the chamber. As the air flows upward, it causes the solid particles within the bed to become suspended and exhibit fluid-like properties. This fluidization creates a boiling effect, where the particles move and circulate freely, facilitating efficient heat and mass transfer.

During the drying process, moisture present in the material evaporates as the hot air comes into contact with the wet particles. The continuous movement and agitation of the particles ensure uniform drying throughout the bed. In the granulation and coating processes, the fluidized bed allows for the even distribution of binder solutions or coating materials onto the particles, resulting in a uniform and controlled growth or coating deposition.

Fluid bed coater

Fluid bed coater

Fluid bed coater

Granulation Process in Fluid Bed Dryer/Granulator/Coater

Granulation refers to the process of forming agglomerates or granules from fine powders or particles. Fluid Bed Dryer/Granulator/Coater provides an efficient and controlled environment for granulation. The process typically involves three stages: wetting, nucleation, and growth.

In the wetting stage, a liquid binder solution is sprayed onto the fluidized particles, promoting adhesion and agglomeration. This step ensures that the particles are evenly coated with the binder, enhancing their binding properties.

Next, in the nucleation stage, the wet particles start to form small nuclei or seed granules. These nuclei act as the foundation for further granule growth. The binder solution, along with the particles, forms bridges between the nuclei, creating stronger bonds.

Finally, in the growth stage, an additional binder solution is sprayed onto the fluidized bed, allowing the granules to grow in size. The controlled addition of the binder ensures uniform growth and prevents over-wetting or excessive agglomeration.

Coating Process in Fluid Bed Dryer/Granulator/Coater

The coating is a crucial process employed in various industries to provide a protective or functional layer on the surface of particles or products. Fluid Bed Dryer/Granulator/Coater offers an efficient and precise coating mechanism.

The coating process begins by fluidizing the particles in the bed. A solution containing the coating material is then sprayed onto the fluidized particles, ensuring uniform coverage. The particles move and circulate within the fluidized bed, allowing the coating material to adhere evenly.

The fluidized bed environment promotes the drying and curing of the coating material, resulting in a solid and durable coating layer. Multiple layers of coating can be applied by repeating the spraying process, leading to enhanced protection, controlled release properties, or modified surface characteristics of the coated particles or products.

Fluidised Bed Coater Construction Material

Hywell Machinery is able to offer our FLP series fluidized bed Dryer / Granulator / Coater with contact parts to be built in SS304, SS316L, Titanium, Duplex stainless steel, etc. For the control system of fluidised bed coaterS, Hywell machinery has choices on push button, PLC+HMI, and so on, and For the main electrical components of the super mixer granulator, it can choices the famous brand such as ABB, Siemens or Schneider, or others.

Fluid Bed Dryer Granulator Coater Advantages 

Hywell machinery FLP series Fluid Bed Dryer / Granulator / Coater had the following advantages over conventional solutions.

1. Bag filter shaking mode of fluidised bed coating: double shaking or air purge type

2. Contact material of fluidized bed coating: SUS316L, inner polishing surface Ra <0.4.

3. Sample taking by sampling device, for ease of sampling.

4. The material bag filter is made of polyester fibers and stainless steel fibers with anti-static electricity conductivity cloth.

5. Multi-purposes: one machine can perform multiple functions, drying, granulation, powder coating, pellet film coating, and pellet enteric coating.

6. Complete discharge and easy cleaning

7. Highly polished inner and outer surfaces of the barrel, no dead comer, easy to discharge materials, easy to clear, no cross-contamination.

8. The powder coating fluidizer has enclosed structure, without overflow of power dust

9. Air inlet system equipped with pre-filter, mid-filter, and HEPA 99.97% 0.3μ to ensure the cleanness of inlet air.

10. Top spray: adopted single-head spray gun, even spray pattern and fast granulation.

11. The Fluid Bed Dryer / Granulator / Coaters have smooth running, reliable performance, and easy operation.

12. The loading and unloading are quick, light, and clean, meeting the requirements of GMP.

13. the Fluid Bed Dryer / Granulators / Coater has the explosion release vent on the machine. once the explosion happened. the machine will release the explosion outside automatically and safely, and it will make very safe conditions for the operator.

14. For the loading materials, it has choices on vacuum feeding, lifting feeding, negative feeding, and manual feeding for customers.

15. This machine adopts PLC automatic control, all the operations according to the requirements of the user to set the process parameters automatically, it can print all the process parameters (optional), and the original record is true and reliable.

16. For the FLP series multifunction granulating coating machine, has CIP for the customer to choose from (Optional).

Fluid Bed Coater Application:

The fluid bed powder coating machine is widely used in the pharmaceutical, chemical, foodstuff, and electronic industries．

Top Spray

Pharmaceutical: For medicines, biopharmaceutical, and Chinese medicine’s granulation or drying.

Food: Instant food, juice powder, seasoning, food additive, lactic acid bacteria’s granulation or drying.

Bottom & Side Spray

 Medicines and healthy food for a controlled release of active ingredients.

Key Features to Consider

When selecting a Fluid Bed Dryer/Granulator/Coater for your specific application, certain key features should be considered:

1. Airflow Control

   The equipment should provide precise control over the airflow, allowing for optimal fluidization and process efficiency.

2. Temperature Control

   The ability to adjust and maintain the desired temperature throughout the drying, granulation, or coating process is essential for consistent results.

3. Spray System

   Different spray systems, such as top spray, bottom spray, or tangential spray, offer distinct advantages for specific applications. Choosing the appropriate spray system ensures effective granulation or coating.

4. Process Monitoring and Control

   Advanced control systems and sensors enable real-time monitoring and adjustment of critical process parameters, ensuring product quality and process optimization.

5. Ease of Cleaning and Maintenance

   The equipment should be designed for easy cleaning, inspection, and maintenance, minimizing downtime

   and maximizing productivity. Accessible and removable parts, as well as user-friendly interfaces, contribute to the ease of maintenance.

6. Safety Features

   The Fluid Bed Dryer/Granulator/Coater should be equipped with safety mechanisms to prevent overheating, overpressure, and other potential hazards. These may include temperature sensors, pressure relief valves, and alarms.

7. Scale-Up Capability

   If you anticipate scaling up your production in the future, it's important to choose a Fluid Bed Dryer/Granulator/Coater that allows for easy scale-up without compromising performance and efficiency.

8. Material Compatibility

   Consider the compatibility of the equipment with the materials you will be processing. Different materials may require specific construction materials or surface treatments to prevent contamination or chemical reactions.

Fluid Bed Dryer / Granulator / Coater Video

Troubleshooting Common Issues

While Fluidized Bed Dryer/Granulator/Coater systems are reliable, you may encounter some common issues during operation. Here are a few troubleshooting tips:

1. Uneven Drying or Granulation

   Check the airflow distribution and adjust if necessary. Ensure proper nozzle alignment and spray pattern for uniform coating or granulation.

2. Poor Coating Adhesion

   Verify the compatibility of the coating material with the particles. Adjust the spray rate and drying parameters to optimize coating adhesion.

3. Excessive Dust or Fines

   Inspect and clean the filter bags or other filtration components. Adjust the airflow to prevent excessive entrainment of fines.

4. Equipment Overheating

   Check for any obstructions in the air ducts or filters that may impede airflow. Verify that the temperature sensors and controls are functioning correctly.

5. Nozzle Blockage

   Clean or replace clogged nozzles to ensure consistent spraying and coating distribution.

Remember, if you encounter persistent issues or require technical assistance, consult the equipment manufacturer or a qualified technician.

Conclusion

Fluid Bed Dryer/Granulation /Coater is a versatile and efficient equipment widely used in industries such as pharmaceuticals, chemicals, and food processing. Its ability to perform drying, granulation, and coating processes in a single unit offers significant advantages in terms of time, cost, and product quality. By understanding the working principle, processes, and key features of Fluid Bed Drying/Granulating/Coater, you can make informed decisions when selecting and utilizing this technology in your manufacturing processes.

Frequently Asked Questions (FAQs)

1. Can a Fluid Bed Dryer/Granulator/Coater be used for both small-scale and large-scale production?

   Yes, Fluid Bed Dryer/Granulator/Coater systems are available in both batch and continuous configurations, making them suitable for various production scales.

2. What are the advantages of using a Fluid Bed Dryer/Granulator/Coating machine over other drying or coating methods?

   Fluid Bed Dryer/Granulator/Coater offers faster drying times, uniform granulation or coating, precise process control, and cost-effectiveness compared to conventional methods.

3. Is it possible to coat particles with multiple layers using a Fluid Bed Dryer/Granulator/Coater?

   Yes, Fluid Bed Dryer/Granulator/Coater allows for the application of multiple layers of coating by repeating the spraying process, providing versatility in achieving desired coating properties.

4. How do I ensure the safety of the equipment and operators during the operation of a Fluid Bed Dryer/Granulator/Coater?

   Fluid Bed Dryer/Granulator/Coater should be equipped with safety features such as temperature sensors, pressure relief valves, and alarms. Operators should also receive proper training and follow safety protocols.

5. Can a Fluid Bed Dryer/Granulator/Coater handle different types of materials?

   Yes, Fluid Bed Dryer/Granulator/Coater can handle a wide range of materials, including pharmaceuticals, chemicals, and food ingredients. However, it's important to consider material compatibility and consult the equipment manufacturer for specific guidelines.