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Fluidized Bed Granulator

The fluidized bed granulation (spray liquid granulator) is a method for making free-flowing granulate from liquids. fluid bed granulation can be used in different applications in various industries since the product properties can be varied in many ways by setting process technical parameters and configurations. The granules made by the fluid bed granulator machinery are suitable for making tablets, and the granules are also for final coating by the fluid bed coating machine.
Many industrial applications require converting liquid substances into a stable product form with exactly defined properties – whether for further processing as a solid for Pharmaceutical, food products, animal feed, or cleansing agents, for increasing stability in chemical substances, or for handling thermally sensitive products such as enzymes, proteins or micro-organisms. Spray granulation in the fluidized bed permits liquids to be directly made into free-flowing granulate with specific product properties. Generally, the granules also have instant properties.

  • FL
  • HYWELL
  • 8479899990
  • SUS304/SUS316L/Titanium
  • Food/Pharmaceutical/Chemical
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Fluidized Bed Granulator Introduction

Hywell Machinery FL Series fluid bed granulator also called fluidized bed granulator, fluid bed granulation process can integrate top spray for granulation and drying in one unit for fluid bed processing.

The Fluid Bed Granulators top spray granulation technology in the production of pharmaceutical solid dosage forms.

Hywell® fluidized bed granulation is composed of an air handling unit, spray system, filter system, material charging system, CIP washing in place system, and so on.

Hywell Fluidized bed granulator machine uses liquids containing solids, such as solutions, suspensions, or melts, which are sprayed into a fluidized bed system. Due to the high heat exchange, the aqueous or organic solutions evaporate immediately, and the solids form small particles as starter cores. These are sprayed with other liquids which in turn, after evaporation, form a hard coating around the starter core.

This step is continuously repeated in the fluidized bed so that the granulate grows layer by layer like an onion. Alternatively, a defined volume of suitable starter cores can be provided. In this option, the liquid only serves as a vehicle for the solids that are being applied.


This process variant is often used in a continuous fluidized bed process with air-classifying discharge. Through the continuous removal of the finished granules from the drying room, the amount of particles in the fluidized bed remains constant.

The granules can be very dense because they have grown in layers, and are thus resistant to abrasion. Parameters such as particle size, residual moisture, and solids content can be specifically adapted in order to achieve the most varying product properties. Using spray granulation, medium-sized particles of 50 micrometers to 5 millimeters can be produced.

The fluidized bed granulator can be used as a drying machine if the spray liquid system does not use to spray liquid.


The fluidised bed granulator can be used as drying machine if the spray liquid system do not use to spray liquid .

Hywell Machinery has laboratory machinery for the factory or experimental agency product development stage, please pay attention to hywell company's laboratory fluid bed granulator.


one step granulator

Fluid Bed Graunulator

fluid bed granulation

Fluid Bed Granulation

fluid bed granulating machine

Fluidized Bed Granulator


A fluidized bed granulator machine is the most critical equipment in the solid preparation production line. Hywell Pharmaceutical Granulation Line for solid dosage forms, includes High Shear Mixer, Wet granulator, Fluid Bed Dryer, Lifting Column, Conical Mill, Vacuum Conveying System, Blender, etc. The top spray granulator as drying equipment in the solid preparation production line mainly uses the drying the wet particle that is made by the high shear granulator. But the top spray granulation can also be used as a single granulator alone. So this top spray granulators not only work as a production line and also as a granulator alone.



Solid Dosage Forms Line


Fluid Bed Spray Granulator 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 is combined in granules will be dried to get the required moisture content.


Top Spray Granulator

The top-spray granulator agglomerates finer particles into larger, free-flowing granulate 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 granulator 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.


Drying of spray drying granulator

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.


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 dryer granulator structures

1. Inlet air system of fluid bed dryer granulator

Constant air purification, temperature, and humidity are among the most important conditions to ensure product quality. Hywell can provide an approach of fluidized bed system modularized unit combination of air handling unit.


The inlet air system of fluid bed dryer granulators consists of dehumidification (Optional), 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, Fluidized Bed Granulation can be a steam radiator or electrical heater. It helps to reduce the effects of humidity change of environmental air to dehumidify the inlet air, thus to ensure fluidized bed drying process efficiency. Another purpose of the filtering is to prevent the air in the fluidizing chamber from flowing back to the heater, easy for cleaning.


The outlet air has been filtered inside the machine. To meet special emission control regulations, we provide various secondary filtering &dust separation plants, such as compound-hydro type.


3

Medium Efficiency Filter

high temperature high efficiency filter

HEPA Filter

HEPA FILTER

HEPA Filter


2. Main Body Structure of fluidized bed dryer granulator

The main body structure of the fluidized bed dryer granulator consists of a bottom bowl, a movable product bowl with a trolley, a fluidized chamber, 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. Spraying system of Fluid Bed Top Spray Granulation

The spray gun is the core of Fluid Bed Top Spray Granulation, which is one of the most important factors affecting the process, like the proportion between ointment and powder in granulates of herb medical fluid extract, bond dosage in granulates of western medicine, granularity distribution, conformity ratio, and coating quality, etc.


Hywell machinery provides spray nozzles of various sizes and optimized structural design, which ensures ideal liquid distribution modes, such as single port spray nozzle, and multi-port spray nozzle, to match different process requirements.


Moreover, the optimized structure and the excellent processing technology make it convenient to operate and clean. The liquid pump will supply a medium for the spray gun. We provide various peristaltic pumps and diaphragm pumps. Moreover, we can choose a special device to preserve the temperature of solutions and atomized air for a specific medium, to ensure the stable characteristic of the medium supplied to the spray nozzle.


spray gun

Spray Gun

spray gun1

Spray Gun

liquid pump

Liquid Pump


4. Product Filter of Fluid Bed Top Spray Granulator

FL Series fluid bed top spray granulator, the basic to smoothly implement the fluid bed process is that the material should be in a good state of fluidization, which will be continued through the highly efficient fluid bed granulation process of powder cleaning.

Single filter chamber or double filter chamber pneumatic shake is available. Because of the special sealing structure and connection mode, it maintains high efficiency in powder cleaning, sufficient enough to carry out difficult process operations.

The pulse counter-blow powder cleaning system is another facility of Hywell machinery, which blows out high-pressure airflow through a special spray nozzle, which implements the process of powder cleaning by circulatory counter-blowing through a filter. The filter has two kinds that are stainless steel filter (optional) and anti-static cloth filter, which makes possess excellent filtering and cleaning performances, extremely high filtering precision (3-5μm), and stainless steel filter have a long use life but it is expensive.

There are two modes for filter cleaning, one is pulsating blowback, and the other is cylinder shaking cloth bag.



cloth filter

Pulsating Blowback Filter

cloth bag filters1

 Cylinder Shaking Filter

fluid bed bag

Pulsating Clean Filter


Pulsating blowback clean dust

Another important feature, which cannot be ignored, is that pulse counter-blow powder cleaning helps to maintain a relatively stable loaded pressure of the fluid bed, which is obviously advantageous in certain process operations.

 

Cylinder shaking clean dust

Another cleaning method is the cylinder shaking bag filter, but it just can only use a bag filter. The best advantage is that the number of cloth bags is one and can be lifted down the filter, and it is easy to exchange cloth bag filters.

As a matter of fact, no matter a sack filter or a canister filter, both can apply air bag sealing, to separate the filter chamber and fluidize, which helps to disassemble the filter very fast and conveniently, also helpful for personnel protection.


Fluid Bed Granulators Specifications

Model

unit

15

30

60

120

200

300

500

Tank

Volume

L

45

100

220

420

670

1000

1500

Diameter

mm

550

700

1000

1200

1400

1600

1800

Load capacity

Min

Kg

10

15

30

80

100

150

250

Max

Kg

20

45

90

160

300

450

750

Air volume

Air volume

M3/h

1400

1800

3000

4500

6000

7000

8000

Air pressure

Mm H2o

480

480

950

950

950

950

950

Power

Kw

5.5

7.5

11

18.5

30

37

45

Steam consumption

Kg/h

42

70

141

211

282

366

451

Compressed air   consumption

M3/Min

0.3

0.6

1.0

1.0

1.2

1.5

2.0

Weight

Kg

900

1000

1100

1300

1500

1800

2500

Size (L×W×H)

M

1.25×0.9 ×2.5

1.6×1.1
  ×2.5

1.85×1.4 ×3

2.2×1.65
  ×3.3

2.34×1.7 ×3.8

2.8×2
  ×4.5

3×2.25
  ×5.0

1.Hywell machinery reserves the right to the design without notice

2.All specifications of fluid bed granulators are as accurate as is reasonably possible, but they are not binding.


Fluidized Granulator Construction Material

Hywell Machinery is able to offer our FL series fluid bed granulators with contact parts to be built in SS304, SS316L, Titanium, Duplex stainless steel, etc. For the control system of fluid bed granulators, 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 that such as ABB, Siemens, or Schneider or others.


How do the Fluidized Bed Granulators works

In a Hywell machinery FL series fluidized bed granulators, The powder granule in a vessel (fluid bed) appears in the state of fluidization. It is preheated and mixed with clean and heated air. At the same time, the solution of adhesive is sprayed into the container. It makes the particles become granulating that contain adhesive. Being of unceasing dry through hot air, the moisture in the granulating is evaporated. The process is carried out continuously. Finally, it forms ideal, uniform, and porous granules.

Fluidized bed granulating Machine is mainly used for the operations of mixing, granulating, and drying of granule "Top Spraying", etc of powder material in the pharmaceutical industry, foodstuff industry, chemical industry, etc. Such as granules of tablets, granules for quick resolving drinking, condiments.

Fluid Bed Dryer Granulator Advantages

Hywell machinery FL series fluid bed dryer granulators had the following advantages over conventional solutions.

1. Adopting a multi-fluid nozzle, guarantees that the formed granule is uniform and the content of powder is very low.

2. Complete discharge and easy cleaning

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

4. The fluid bed granulator has enclosed structure, without overflow of power dust

5. The fluid bed granulators have smooth running, reliable performance, and easy operation.

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

7. the fluid bed granulating machine has an explosion-release vent on the machine. once the explosion happened, the machine will release the explosion outside automatically and safely, which will make a very safe condition for the operator.

8. For the loading materials of the fluidized granulation machine, it has choices on vacuum feeding, lifting feeding, negative feeding, and manual feeding for customers.

9. The fluidized granulating 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. In full compliance with the GMP requirement of pharmaceutical production.

10. For the bag filter, choose an anti-static filtering cloth. Adopting a double chamber filtering bags system removes dust completely.

11. For the fluid granulating machine, has CIP for customers to choose (Optional).

12. The processes of mixing, granulating, and drying are completed in one step inside the machine. So fluid bed granulation also names as one-step granulator or one-step granulation.


Fluidized Granulation Application:

The FL series fluidized granulations are widely used in the pharmaceutical, chemical, foodstuff, and electronic industries.

1. Western medicine

Granulating and drying before tableting.


 2. Chinese medicine

Granulating and drying of concentrated granules.


3. Food

Granulating and drying of instant food, instant health food, coffee, cocoa, milk powder, fruit flavor powder, and seasoning.


4.  Chemical

Granulating and drying of pigment, dye, synthesis raw material.


Fluidized Granulator Machine Conclusion

Hywell machine is a leading FL fluid (fluidized) bed granulator manufacturer and supplier, we always do not let you down, as we trying to build up our brand which is associated with feedback from you, so your satisfaction is our motivation. We persist driven to satisfy, driven to the fluidized bed granulator machine that exceeds your expectations in price, quality, and delivery. If you are looking for any capacity of fluidized bed granulations, you’ve come to the right place, and contact Hywell Machinery right now.


materials tank

Materials Cart

control panel

Control Panel

CIP spray gun

Foundation CIP


Fluid Bed Granulation Video





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