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Solid Dosage Granulation Line

Integrated Granulation and Drying for Solid Dosage production is one granulation line for pharmaceutical solid dosage forms.
Solid Dosage Granulation Line is a common technique in the production of pharmaceutical solid dosage forms. Due to the high-quality requirements of the formed granules in terms of content uniformity and physicochemical properties, it is important to choose the right process. The wet granulations process will ensure that a fine-powder heterogeneous mixture will turn into a uniform granulation, with increased particle size and higher density.
  • GL
  • HYWELL
  • 8479899990
  • SUS304/SUS316L/Titanium
  • Food/Pharmaceutical/Chemical
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Complete Solution for Solid Dosage Granulation of Tablets

The Solid Dosage Granulation Line from Hywell is a single-frame solution that carries out all options for the wet granulation process. It integrates the High Shear Granulator for mixing and granulation, the Fluidized Bed Dryer for drying, granulation, and coating, and the Conical and Cylindrical Calibrators for calibration. It thus helps in reducing the space required in the clean room and minimizing the risks of cross-contamination while giving maximum flexibility to process development and scalability studies.


The pharmaceutical solid dosage granulation line forms are available in capacities ranging from 45 L to 1500 L and can carry out two different processes. The first is wet granulation where an agglutinative solution is added to form granules. The equipment combines one or more dust particles and forms a granule within the required limits.


The second is the drying process by fluidization bed dryer which is widely used in the pharmaceutical industry to reduce the moisture content of powder and granules. Hot air is passed at a given pressure and flow rate through a perforated bed of moist solid particles. The wet solids are lifted from the bottom and suspended in a stream of air. Heat is transferred by direct contact between the wet solid and hot gases. The vaporized liquid is then carried away by the drying gasses.


Wet granulation is a widely used process in the pharmaceutical industry since this improves the flow properties, homogeneity, and compressibility of the powder mix. Fluidized bed granulators and high-shear mixers are typically used in traditional batch wet granulation processes.


Oral Solid Dosage Granulation Line Description

If you are in the pharmaceutical manufacturing industry, then you should consider buying this premium solid dosage granulation machine. This pharmaceutical granulation equipment will ensure there is no cross-contamination.

Solid oral dosage granulator combines mixing, granulation, and drying processes to ensure continuous and stable production, The granulation drying production line can highly increase the yield of finished products.

The vacuum conveying device and lifting turnover discharging system can greatly decrease labor intensity and avoid dust pollution. it means that the Granulator drying production line saves on the cost of labor.

Hywell machinery oral solid dosage equipment (wet granulation line system) adopts automatic PLC control with the graphical interface. This means that the operation and process parameters can be set automatically for history review and print.

The CIP system in the solid dosage form granulation line can fulfill well cleaning effect for the granulator and dryer. The ex-proof system, reliable interlock, and earthing ensure the safety of the people, equipment, and environment.

If you would like to buy a custom solid-dose pharmaceutical manufacturing line, Hywell will work hard to meet the process and specifications. We can customize the designs and sizes of granulation lines.

Please note that we sell these reliable wet granulating lines to customers who deal in food, chemical, and pharmaceutical products. With us, location is not a barrier. We even make it possible for customers who would like to order this solid dose granulation line online.

Would you like to buy this solid-dose manufacturing process line? then Send your inquiry on Hywell machinery right now. Hywell company is a reliable and reputable solid dosing granulation line manufacturer in China. Hywell Machinery Co., Ltd will support with Project Initial design — Project Initial confirm — Project detailed design — Project confirm — Select Equipment specification. To provide the advanced service for customers, and to insure all the machines are suitable for each production line of customers.


Solid Oral Dosage Granulator Line Composition

Nowadays, Solid dosage production lines also called continuous fluid bed granulation, and high shear granulator lines take a more and more important role in pharmaceutical granulation equipment.

Hywell focuses on integrated granulation and drying for solid dosage production with 20+ experience.


Hywell Granulation line for pharmaceutical solid dosage forms, includes High shear mixer granulator, Wet conical mill/wet granulator, Fluid bed dryer/granulator, Lifting column/Hopper Elevator, Dry conical mill, Vacuum conveying system, Powder Mixer/Hopper Mixing machine, etc.


The high-shear mixer granulation machine and wet conical often install together as high-shear granulators and directly transfer the wet granules into the fluid bed drying machine.


The fluidization bed dryer often uses the fluid bed processor (fluid bed granulator/dryer/coater) or fluid bed granulator to replace the fluid bed dryers inside the solid dosage forms processing line. The reason is very simple the fluidization granulator machine not only has the function of drying equipment, but it also has the function of a liquid spray granulator. One machine achieves two purposes. Off course, The boiling (fluid bed) granulation coating dryer integrates the granulation machine, granules coating machine, and drying machine functions. However, Different hoppers are required for the coating function, if the workshop is narrow or this equipment never be used for coating for the workshop, so they will choose a boiling granulator to reduce the cost.


As a complete solid dosage wet granulation process manufacturer of premium processing technology systems with 20 years of experience in the development and manufacture of solids, continuous processing becomes more and more important in the pharmaceutical, health products, food, fine chemical, and feed processing industry.




high shear granulation line

1. High shear mixer granulator

The High Shear Mixer Granulator of the solid dosage forms manufacturing line is designed to optimize the wet granulation process. Used to turn a fine-powder heterogeneous mixture into a uniform granulation, with increased particle size and higher density, offering proper flow and compactness properties, in a short time process and with repeatability.


The powder material can be manually added into the high-speed mixer silo, or the powder can be sucked into the high-speed mixer by a vacuum feeder. At the same time, the powder is stirred by the high-shear mixer and the liquid is poured into the silo pass the liquid tank; but the liquid in the liquid tank is usually driven into the silo by a pump (optional). The high-speed mixing machine will work automatically according to the set program.

High Shear Granulator

2. Wet granulator / Wet conical mill

After the high shear granulator is finished, the discharge port cylinder opens the discharge valve, and the wet powder is discharged into the wet granulator (Wet conical mill) at the lower, the wet granulation machine will make the wet powder into uniform wet granules, and wet particles are discharged from the discharging port of wet granulating machine (wet conical mill). The wet granulator also names a wet conical mill which is a core mechanism for the solid dosage processing line.


3. Fluid bed dryer/ Fluid bed granulator

The wet granules are sucked from the wet conical mill using a fluid bed dryer exhaust fan with negative pressure and transported to the fluidized bed dryer with the process air. The fluid bed dryers are a drying process for the granulation drying production line and also essential equipment.

The fluidization process is used extensively in the pharmaceutical industry to reduce the moisture content of powder and granules in a drying process.

In this process, hot air is introduced at defined pressure and flow rate through a perforated bed of moist solid particles.

The wet solids are lifted from the bottom and suspended in a stream of air (fluidized state).

Heat transfer is accomplished by direct contact between the wetted solid and hot gases.

Wet granular moisture will be taken away by the hot air, the wet granular will be dried and then the fluid bed granulator will be turned off by the control system.


fluid bed processor


4. Lifting Column / Hopper Elevator

Hywell machinery boosts the efficiency and mobility of your handling systems. We provide a range of equipment for modern and effective product handling that includes a great variety of mobile and stationary lifting and discharging devices. It can work with Bin Blender, a tablet machine. the lifting column will lift the fluid bed granulator materials cart and then directly discharge the dried granules into the powder blender or powder vibration sieve.

5. Conical Mill

The conical mill also called the lifting conical mill, the conical mill is mainly used for obtaining evenly qualified granules through sieving agglomerates from granulators. The cone mill is easy to operate and clean, and it fully complies with GMP.


6. Other machinery

According to material characteristics and customer requirements, this granulation production line can be equipped with a vacuum conveyor, powder screening machine, and powder mixer. For detailed options, please consult Hywell Machinery Co., Ltd.


7. Documents

Hywell machinery customizes all documentation related to the granulation line equipment, making easier the training, operation and maintenance of the equipment through the life term even in the more exigent industries as the pharmaceutical market, we provide a complete set GMP including DQ, IQ, OQ, SAT, FAT, USER manual documentation.

If you want to start in Pharmaceutical granulation production line business, please contact us for more details, we will send you detail specification, quotations, layout drawing for equipment.


Solid Dosage Granulators Line Specifications

Model

GL-30

GL-60

GL-120

GL-200

GL-300

Capacity

30

60

120

200

300

Equipment composition

HS-3

HS-3

HS-4

HS-5

HS-7

GHL-100

GHL-200

GHL-400

GHL-600

GHL-800

GZL-100

GZL-180

GZL-180

GZL-300

GZL-350

FG-30

FG-60

FG-120

FG-200

FG-300

HS-3

HS-3

HS-4

HS-5

HS-7

1. One High Shear Mixer can be with two fluid bed granulators & dryers

2.The FG fluid bed dryer can be replaced by the fluid bed granulator or fluidized dryer/granulator/coater.

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

4. All specifications of solid dosage granulators line are as accurate as is reasonably possible, but they are not binding.


So How Does The Solid Dosage Granulation Line Work?

In batch processes, several machines are used for different processes with pauses between processes for the operator to perform processes such as sampling or product transfer.

Continuous processes are more autonomous. And multiple processes can be carried out with the same equipment. It means that several processes such as loading, granulating, drying, coating, and sizing are carried out in the fluid bed granulator. Granulating, wet cone mill, drying, coating, lifting, transferring, dry cone mill, blending in the same solid preparation granulator lines.

This solid preparation granulator lines for a product factory, one high shear mixer granulation machine with one fluid bed processor, and one custom combine pharma lifter and vacuum conveying with a cone mill.


Solid Dosage Forms Granulation Line Material

Hywell Machinery are able to offer our Solid Dosage Forms Granulation line with contact part to be built in SS304, SS316L, Titanium, Duplex stainless steel, etc. Electrical parts of control system of the Solid Dosage Forms Granulators line can be adapted to the customer's needs.


High-shear mixer granulator and fluidized bed dryer for solid preparation granulation line

One shear mixer granulator + one fluid bed dryer

The high shear mixer granulator was connected to one fluid bed granulator or fluid bed dryer.

high shear granulation process



One high shear mixer granulators + two fluid bed dryer

Hywell also supply a granulation line where the high-shear mixer granulators are connected to two fluid bed granulators or dryers.

Granulation Process Line


One high shear granulator + more fluid bed dryer

Hywell can even have one high-shear granulation connected to more than two fluid bed granulators or dryers.


Advantages of the oral solid dosage wet granulation line

The oral solid dosage wet granulation line is mostly used to prepare solid dosage forms due to its many advantages as follow:

1. Better flowability of particles since it forms more spherical granules.

2. The granules’ compressibility is also improved since it reduces air entrapment in the granules.

3. For low-dose drugs, it provides better uniformity.

4. It also improves the dissolution rate of soluble drugs.

5. Wet granulation produces tablets that are suitable for further post-processing methods including tablet coating.

6. With a high degree of containment and the use of binder fluids, there is less dust pollution during the manufacturing process. Thereby, there is less chance of contamination.

7. Our granulation from a high-shear mixer, fluid bed dryer, lifting column, and bin blender happen in a closed container with no material loss and dust pollution.


Disadvantages of the oral solid dosage wet granulation line

While the wet granulation line process is the most employed, it is also subject to some limitations:

1. It’s unsuitable for active ingredients that are sensitive to moisture.


Solid Dosage Manufacturing Technology

Pharmaceutical manufacturing is a highly controlled and regulated process. Almost every process can be automated and there have been rapid and continuous advancements in the solid dosage manufacturing processes. Major manufacturers are constantly assessing their competitiveness to ensure constant growth in an ever more demanding market where the cost of developing novel products is continuously increasing. There has been an urgent need for pharma companies to continuously invest in innovative processes to produce solid dosage forms that better meet the needs of the patient and are efficiently manufactured.

Oral dosage forms including tablets and capsules are considered the most patient-acceptable dosage forms in the market today. They offer convenience and ease of handling and are also extremely stable, both chemically and physically. Production of these solid-dosage drugs is also relatively inexpensive and high throughput is well achieved.

A pharmaceutical granulation line is necessary to overcome the significant compression difficulties and erratic flow properties of many active pharmaceutical ingredients that limit the successful production of these dosage forms.


Granulation Definition of the solid dose manufacturing process

It’s very simple to understand the granulation process in tablet manufacturing. Simply, it’s the formation of granules from smaller particles.

At the heart of the tablet manufacturing process is the granulation process. The desired outcome after granulation is dust-free granules. it is easy to compress into tablets than smaller grains by the tablets machine.

we can do the one-stop solution for efficient and productive pharmaceutical lines. Our solid dosage forms will be the pillar of your factory bringing in many benefits including excellent products, reduced production costs, and stability, among other advantages.

1. Granulation Techniques

Granulation helps promote the flowability, compressibility, bioavailability, and homogeneity of the powder mix. There are different granulation methods and techniques, which influence the properties of the granules. The popular granulating method is dry granulation and wet granulation.

Tests have shown that direct compaction leads to problems with the flow of powder and the grains stick to the surface of machines during compression.

Wet granulation also called high-shear mixer granulation tends to be the most preferred process. High shear granulation forms granules that are harder and dense. Although they are tougher to mill, high-shear pills have slower release times, which improves their efficacy and availability.


1). High shear granulation machine

The high-shear granulation process is wet because a liquid is added to the mix to help create bonds between grains to form granules.

Binder liquids often use the is Ethanol, Water, Organic solvents (isopropanol and ethanol), and so on.

Since they evaporate rapidly at lower temperatures than water, the powder mix dries quickly when they are used. However, organic solvents are more costly than water. It’s also more challenging to dispose of them after production.

Hywell machinery can recommend binder liquids according to your process requirements.

Next, let’s look at the process steps for high shear mixer granulator:

Granulation with a high shear mixer

The main parts of the high shear mixer include the follow parts:

Dome-shaped stainless-steel mixing bowl

Inside the bowl, it will find the impeller and chopper. The mixing bowl may have jacketed-walled (as an optional item), where hot or cold liquids can be channeled through, to heat or cool the contents of the bowl.

Impeller

The impeller consists of two or more blades. We normally design three-blade impellers. It agitates the power mix to distribute the granulation fluid evenly. It has a low rotation speed of 5 rpm-300 rpm.

Chopper

The chopper of the high shear mixer has smaller blades than the impeller. It’s usually fitted on the side or at the bottom of the dome-shaped bowl. it is to shred the wet mass of powder into granules. It has a higher rotation speed from 200- 3000 rpm.

Wet cone mill (wet granulator )

The wet cone mill is available as an optional item. It mills granules produced by the wet granulator into smaller particles before drying.

An explosion-proof high shear mixer granulator design is also available if you need it.

Here are the production steps for the high-shear mixer. about the full detail of the high-shear mixer, please check our high-shear granulator guide.

Loading /charging process

The first process step of the high shear granulation is loading powder into the bowl. it either load a premixed powder or the mixing can be done inside the bowl by loading all the ingredients and running the impeller at full speeds for two to five minutes.

There are two ways to feed the ingredients; gravity feeding is done manually or vacuum feeding using a vacuum conveyor which we use in our high shear mixer.

Spray the binder

After mixing, the binder is added to the powder mix. The chopper and impeller are decelerated for this step to ensure even distribution of the binder fluid.the binder can use manually or liquid pump to send inside the bowl.

Granulation by rotating rotors

After applying the liquid binder, the impeller and chopper are then accelerated to full production speeds for the granulation process.  granules growth then occurs.

Our high-speed mixer is equipped with a wash-in-place system (as an optional item) that will efficiently clean the high-granulator without disassembling the impeller or chopper.

2. Drying the granules

There are several ways to dry granules after granulation; a tray drying machine was a method used in the past, but it was only suited for small amounts of product. It was inefficient since it produced uneven drying. It was also labor-intensive and time-consuming. but the machine is a small and cheaper investment and for small batches that are the best granules drying machine.

Now, most of the drying is performed in fluidized bed dryers. You can also use the fluid bed processor. The fluid-bed drying technique has more advantages than drying granules in an oven.

1). Fluid bed dryer

What is the principle of the fluidized bed dryer granulator?

It works by blowing a stream of dehumidified and dried air from the bottom of the fluid bed dryer base part.

The wet mass of granules is discharged over this bed of air. There is a fine mess on the upper section of the dryer to prevent the particles from escaping.

When the granules have attained the required qualities in terms of moisture level, they are emptied and transferred to the next process equipment.

The fluid dryer is then filled with a new batch of wet granules. It dries materials much faster. Learn more about the fluid bed dryer.

the fluid bed drying system, etc of granulation lines available share one WIP system(optional item).


3.Transferring granules

From the fluid bed dryer or fluid bed granulator, the granules have to be transferred. There are three ways to do this:


1) Manual unloading

This method is the most popular method in the past from fluid bed drier, but it is labor-intensive and dusty. It is no longer the most popular cutting method.


2). Vacuum conveyor

It involves using a vacuum conveying to transfer the materials from the fluid bed dryer into another bin using a feeder tube. vacuum conveying has several advantages such as efficient use of space and reduced dust levels.


3). Lifting column

Hywell machinery manufactures several types of lifters that are used for discharging and transporting materials from the fluid bed dryer.

You can learn more about the lifting columns here.


4. Cone Mill

Cone Milling is the process of breaking down lumps of agglomerated granules into smaller sizes. Milled granules have to be sieved by vibration sieve to ensure they conform to the required standards.

The main features of the cone mill are an impeller and a screen for filtering granules. The impeller is rotated by a motor and impacts kinetic energy on the lumps of granules.

The sheer force causes the mass to fracture and the granules fall on the screen –that’s made up of a series of holes with the preferred aperture size.

While the main aim of milling is size reduction, it also achieves other functions such as creating uniform particles with great flowability.

At Hywell machinery, we supply cone mills that be installed inline. You can learn more about the bin cone miller here.


5. Powder Blending machine

Hywell has different kinds of powder blenders; IBC bin powder mixer, fixed bin powder mixer, 3D mixer, drum powder blender ,and Laboratory Bin

We often use the IBC Bin blender as the granulation production line.

The bin blender carries out clamping, lifting, tilting, and mixing of granules with the lubricant.

You’ll get uniform mixing, and the bin blender has several safety features. but the most important item that the bin can transfer to a different place and also be interchanged.



granulation line equipment


Our services

Our pre-sales and after-sales services make it easy for customers to acquire and use our granulation processing equipment.

Our engineers can offer assistance during regular equipment maintenance, provide fluid bed granulation troubleshooting, and even handle on-site repairs.

We also offer training for operators to help them maximize your factory’s efficiency.


Contact Us

Reach out to our professional support team by sending a request on our contact page, and tell us more about your needs. You can also send an email to sales@hywellco.com or call us at +86-13382828213


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