Rotary Granulators: A Comprehensive Guide

1.What is a Rotary granulator?

A rotary granulator is a type of granulation equipment used to produce uniform and consistent granules from powders or other raw materials. and rotary granulator also named as basket granulator. The equipment consists of a cylindrical vessel or "basket" with a rotating impeller or agitator located at the bottom of the basket. The impeller rotates at high speeds, causing the materials inside the basket to be lifted and thrown against the walls of the basket.

The walls of the basket have holes or perforations of a specific size, which allows the granules to pass through while retaining any oversized particles. This process of granulation is known as wet granulation, as it involves adding a liquid binder to the raw materials to create a granulated product.

Rotary Granulator

Rotary granulator

Lab Basket Granulator (Rotary granulator) video

ZL-300 Rotary granulator Video

Rotary granulator used in production line

ZL series basket granulator is usually the key equipment of the wet granulation production line. The pellet production line includes the following equipment: CH saga mixer or GHJ high shear mixer, YK series oscillating granulators or ZL series basket granulator, dryer (such as vibrating fluidized bed dryer, static fluidized bed dryer, vertical fluid bed dryer, or hot air oven), and vibration sieve. This production line can make the dry powder into uniform and instant granules. If the customer wants to make the final pellets into a ball shape, the wet pellets will be sent to the QL pelletizer to obtain wet pellets and dried by a dryer. For example, this production line is used for instant tea granules, additive granules, etc.

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

2. How does a Rotary granulator work?

The process of granulation in a rotary granulator can be divided into several steps:

1. Preparation: The raw materials are mixed together and a liquid binder is added to form a wet mass.

2. Loading: The wet mass is loaded into the rotary granulator.

3. Granulation: The impeller at the bottom of the basket rotates at high speeds, causing the wet mass to be lifted and thrown against the walls of the basket. The binder acts as an adhesive, causing the particles to stick together and form granules.

4. Screening: The granules pass through the holes in the walls of the basket, while any oversized particles are retained.

5. Drying: The granules are dried to remove any remaining moisture. it can use our fluid bed dryer, such as vibrting fluid bed dryer, vertical fluid bed dryer.

6. Discharge: The granules are discharged from the rotary granulator and collected for further processing or packaging.

3. Advantages of Rotary granulators

There are several advantages to using a rotary granulator:

1. Uniform granule size

   Rotary granulators produce granules of a consistent size and shape, which is important      in industries such as pharmaceuticals, where product quality and consistency are critical.

2. High efficiency

   Rotary granulators can produce large quantities of granules quickly and efficiently, making them ideal for large-scale production.

3. Flexibility

   Rotary granulators can handle a wide range of materials and can be easily adjusted to produce different granule sizes.

4. Low maintenance

   Rotary granulators are relatively easy to maintain and clean, with few moving parts that require regular servicing.

4. Disadvantages of Rotary granulators

There are also some disadvantages to using a rotary granulator:

1. Limited capacity

   Rotary granulators are typically limited in capacity compared to other types of granulation equipment.

 2. High cost

   Rotary granulators can be more expensive than other types of granulation equipment, especially for larger production capacities.

  3. Moisture sensitivity

  Rotary granulators rely on the addition of a liquid binder to create granules,  which can make the process more sensitive to variations in moisture content.

5. Factors to Consider When Choosing a Rotary granulator

When choosing a rotary granulator, there are several factors to consider:

1. Capacity

   The capacity of the rotary granulator should be appropriate for your production needs.

2. Granule size

   The size of the granules produced by the rotary granulator should be appropriate for your application.

3. Material compatibility

   The rotary granulator should be compatible with the materials you are using, including the binder and any other additives.

4. Maintenance requirements

   The rotary granulator should be easy to maintain and clean, with few moving parts that require regular servicing.

5. Cost

   The cost of the rotary granulator should be within your budget, taking into account both the initial purchase price and any ongoing maintenance costs.

6. Types of Rotary granulators

There are several types of rotary granulators available, including:

1. Fixed-rotary granulators

   These have a stationary basket and a rotating impeller.

2. Pivoting-rotary granulators

   These have a pivoting basket that can be tilted to facilitate loading and unloading.

3. Oscillating-granulators

   These have a horizontal rotating cylinder that oscillates back and forth, causing the materials to be granulated.

7. Maintenance and Cleaning of Rotary granulators

To ensure the longevity and efficiency of your rotary granulator, it is important to perform regular maintenance and cleaning. This includes:

1. Regular inspection of the impeller and basket for wear and damage.

2. Lubrication of any moving parts.

3. Cleaning of the basket and impeller to remove any residual materials.

4. Replacement of any worn or damaged parts.

   
   

8. Applications of Rotary granulators

Rotary granulators are used in a variety of industries, including:

1. Pharmaceutical manufacturing

   Rotary granulators are commonly used in the production of tablets and capsules.

2. Food manufacturing

   Rotary granulators can be used to granulate ingredients for food products such as  seasoning blends.

3. Chemical manufacturing

   Rotary granulators can be used to produce granules for fertilizers, detergents, and other chemical products.

9. Conclusion

In conclusion, rotary granulators are a versatile and efficient type of granulation equipment that can be used in a variety of industries. When choosing a rotary granulator, it is important to consider factors such as capacity, granule size, and material compatibility, as well as the maintenance and cleaning requirements and overall cost.

10. FAQs

 What materials can be granulated using a rotary granulator?

• Rotary granulators can handle a wide range of materials, including powders, crystals, and other solid materials.

What is the maximum capacity of a rotary granulator?

• The maximum capacity of a rotary granulator will depend on the specific model and manufacturer. Capacities can range from a few kilograms to several hundred kilograms per      hour.

How often should a rotary granulator be cleaned?

• Rotary granulators should be cleaned regularly to remove any residual materials that could affect product quality. The frequency of cleaning will depend on the specific application and production schedule.

Can rotary granulators be used for both wet and dry granulation?

• Rotary granulators are primarily used for wet granulation, but some models can also be used for dry granulation.

Are rotary granulators suitable for small-scale production?

• Rotary granulators can be used for small-scale production, but their capacity may be limited compared