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Fluidized Bed Granulator

The fluidized bed granulation (spray liquid) 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 that maked by the fluid bed granulator machinery are suitable for making tablets , and the granules 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 Granulator top spray granulation technology in the production of pharmaceutical solid dosage forms.

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

Hywell machine Fluidized bed granulator machine use the liquids containing solids, such as solutions, suspensions or melts, 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 system 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 fluid bed granulator can be used as drying machine if the spray liquid system do not use to spray liquid .

Hywell Machinery have the 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


Fluid bed granulator is the most critical equipment in the solid preparation production line. Hywell Pharmaceutical Granulation Line for solid dosage forms , it includes High Shear Mixer, Wet granulator, Fluid Bed Dryer, Lifting Column, Conical Mill, Vacuum Conveying System, Blender, etc. The top spray granulator as a drying equipment in the solid preparation production line mainly uses the drying the wet particle that 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 it also as a granulator alone.


Solid Dosage Forms Line


Fluid Bed Spray Granulator Description

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


Top Spray Granulator

The top-spray 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 granulator can also be used for top-spray coating, layering from liquids and instantizing. Special features include a selection of air distributors and one-pot processing.


Drying of Fluid bed spray 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 as the highest priority. Due to 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 Spray Granulator Structures

1. Inlet air system

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

The inlet air system consists of dehumidification (Optional), Primary filter, Intermediate filter, high temperature high efficiency filter(H13 )and heater with accurate temperature control. The inlet air flow, speed and pressure is variable and controllable. For the heater of Fluid bed granulation, Fluidized Bed Granulation can be steam radiator or electrical heater.. It helps to reduce effects from 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 fluidizing chamber flowing back to 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 plant, such as compound-hydro type.


3

Medium Efficiency Filter

high temperature high efficiency filter

HEPA Filter

HEPA FILTER

HEPA Filter


2. Main Body Structure

The main body structure of fluid bed spray granulator consists of bottom bowl, movable product bowl with trolley , fluidized chamber, expansion chamber/filter housing. The bottom bowl, product container and fluidized chamber are inflatable silicon gasket sealed with compress air inspection sensor to assure the reliable sealing.


3. Spraying system

Spray gun of is the core of bed dryer granulator, which is one of the most important factors affecting the process, like proportion between ointment and powder in granulates of herb medical fluidextract, 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, multi-port spray nozzle, to match with different process requirements.

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


spray gun

Spray Gun

spray gun1

Spray Gun

liquid pump

Liquid Pump


4. Product Filter

FL Series fluidized bed dryer 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 high efficient fluid bed granulation process of powder cleaning.

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

Pulse counter-blow powder cleaning system is another facility of Hywell machinery, which blows out high pressure air flow through a special spray nozzle, which implements the process of powder cleaning by circulatory counter-blowing through a filter. The filter have two kinds that is stainless steel filter (optional) and anti-static cloth filter, which makes it possess excellent filtering and cleaning performances, extremely high filtering precision (3-5μm), and stainless steel filter have 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 lift 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 the air bag sealing, to separate the filter chamber and fluidizing, which helps to disassemble the filter very fast and conveniently, also helpful for personnel protection.


Fluid Bed Granulator 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 are as accurate as is reasonably possible, but they are not binding.


Fluid Bed Granulators Construction Material

Hywell Machinery are able to offer our FL series fluid bed granulators with contact part to be built in SS304, SS316L, Titanium, Duplex stainless steel, etc. For the control system of fluid bed granulators, Hywell machinery have 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 Granulator works

In a Hywell machinery FL series fluidised bed granulator, The powder granule in 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 contains 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.

Fluidised bed granulator is mainly used for the operations of mixing, granulating, drying of granule "Top Spraying", etc of powder material in pharmaceutical industry, foodstuff industry, chemical industry, etc. Such as granule of tablet, granule for quick resolving drinking, condiment.



Fluid Bed Dryer Granulator Advantages

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

1. Adopting multi-fluid nozzle, it 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 have enclosed structure, without overflow of power dust

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

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

7. the fluid bed granulating machine have the explosion release vent on the machine. once the explosion happened , the machine will release the explosion to outside automatically and safely ,it will make very safe condition to the operator .

8. For the loading materials of the fuidized granulation machine, it have choices on vacuum feeding, lifting feeding, negative feeding and manual feeding for customer .

9. The fluidized granulating machine adopts PLC automatic control, all the operation according to the requirements of the user to set the process parameters automatically, it can print all the process parameters (optional), the original record is true and reliable. In full compliance with the GMP requirement of pharmaceutical production.

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

11. For the fluid granulating machine,  It have CIP for customer to choose (Optional).

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


Fluidized Granulator Application:

The FL series fluidized granulator is widely used in pharmaceutical, chemical, foodstuff and electronic industries.

1. Western medicine

Granulating and drying before tableting.


 2. Chinese medicine

Granulating and drying of concentrated granule.


3. Food

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


4.  Chemical

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


Fluidized Granulator Machine Conclusion

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