Fluidized bed granulators have become a cornerstone in industries such as pharmaceuticals, chemicals, and food processing due to their exceptional capabilities in creating uniformly coated granules with controlled properties.
In this technical blog, we will delve into the world of fluidized bed granulators, exploring their various types, specifications, and applications.The evolution of the fluidized bed since 1988 has brought about a unique transformation within the pharmaceutical industry.
Originating as an immensely efficient dryer, the concept of fluidized bed spray drying granulation swiftly progressed, incorporating the utilization of spray guns.
we delve into the intricacies of fluidized bed granulators, their operational principles, applications, advantages, and challenges.
Applications of Fluidized Bed Granulators
Fluidized bed granulators find applications across diverse industries:
- Pharmaceutical Tablet Manufacturing : Fluidized bed granulation is a pivotal process in pharmaceutical manufacturing. It facilitates the production of uniform granules that can be compressed into tablets with consistent drug content and dissolution profiles. Controlled coating is also essential for taste masking and controlled release formulations.
- Fertilizer Production : In the agricultural sector, fluidized bed granulators are used to agglomerate and coat fertilizer particles. This enhances their flowability, reduces dust generation, and improves the controlled release of nutrients into the soil.
- Food Powder Agglomeration : The food industry employs fluidized bed granulation to agglomerate powdered ingredients, such as instant beverage powders or seasoning blends. This process improves solubility, dispersibility, and texture, enhancing the overall quality of the final product.
- Chemical Powder Coating : Chemical industries utilize fluidized bed granulators for coating fine particles with protective layers, improving stability and preventing degradation. This is crucial for applications in catalysts, pigments, and specialty chemicals.
Specifications and Considerations
When working with fluidized bed granulators, several specifications and considerations come into play:
- Particle Size and Distribution: The initial particle size distribution influences the final granule size distribution. A narrow particle size distribution enhances process efficiency and product uniformity.
- Airflow Rate and Temperature: Proper control of airflow rate and temperature is critical for maintaining the desired fluidized state and ensuring efficient drying or coating.
- Binder or Coating Solution: The choice of binder or coating solution and its properties (viscosity, solubility, etc.) impacts the agglomeration or coating process.
- Scale-Up Considerations: Successful scale-up from lab-scale to production requires careful adjustment of operational parameters and equipment design.
Fluidized bed granulators offer a dynamic and versatile platform for a range of granulation and coating processes across industries.
By understanding the specifications, types, and considerations associated with fluidized bed granulators, manufacturers can optimize their processes and create products with enhanced quality and performance.
Certainly, there are several types of fluidized bed granulators, each with its unique design and functionality. Here are the main types:
- Top Spray Granulators: Top spray granulators are the most common type of fluidized bed granulators. In this configuration, the granulating solution or binder is sprayed from above onto the fluidized bed of particles. The particles are suspended in the upward flow of air, and the liquid droplets adhere to the particles, leading to agglomeration or coating. Top spray granulators are versatile and can be used for processes like agglomeration, particle coating, and drying.
- Bottom Spray Granulators (Wurster Coaters): Bottom spray granulators, also known as Wurster coaters, operate by spraying the granulating solution from below the fluidized bed. The particles are suspended in a vertical column of air, allowing for efficient encapsulation of individual particles. This configuration is particularly suitable for coating delicate or sensitive particles, as it reduces the risk of particle breakage during the coating process.
- Fluidized Bed Coaters: Fluidized bed coaters are primarily used for applying coatings to particles. They utilize the fluidization principle to suspend the particles while the coating material is sprayed onto them. This results in uniform and controlled coatings on the particle surfaces, enhancing characteristics like controlled release and stability.
- Spouted Bed Granulators: Spouted bed granulators are a variation of fluidized bed granulators where the air is introduced through a spout at the bottom of the bed. The particles are then lifted and fluidized, creating a "spouted" effect. Spouted bed granulators are used for various processes, including granulation, drying, and coating.
- Rotary Fluidized Bed Granulators: Rotary fluidized bed granulators combine the features of fluidization and rotary motion. The particles are fluidized by the air while the equipment rotates, promoting even distribution of the coating or binder material. This type is often used for larger-scale industrial applications.
- Combination Granulators: Some fluidized bed granulators are designed to perform multiple processes in a single unit. For instance, they might have both top and bottom spray capabilities, allowing for greater process flexibility.
Certainly, here's a tabular representation of the key features of fluidized bed spray granulation in the pharmaceutical industry:
| Key Features | Description |
| Evolution | Fluidized bed technology has transformed from a highly efficient dryer to encompass spray drying and granulation. |
| Spray Technology | Incorporates advanced spray gun technology for precise and controlled distribution of granulating solutions. |
| Components | Comprises essential components like the air handling unit, spray system, filter system, material charging, etc. |
| Air Handling Unit | Controls and regulates the air flow and temperature within the fluidized bed, ensuring optimal processing. |
| Spray System | Facilitates the uniform spraying of granulating solutions onto fluidized particles for agglomeration or coating. |
| Filter System | Removes excess particles and contaminants from the exhaust air, maintaining a clean processing environment. |
| Material Charging System | Introduces the initial material into the fluidized bed, initiating the granulation or agglomeration process. |
| Washing in Place (WIP) System | Enables automated cleaning and maintenance of the equipment, enhancing efficiency and adhering to hygiene. |
| Safety Measures | Incorporates safety protocols to ensure the well-being of operators and prevent accidents during operation. |
| Process Flexibility | Offers versatility to perform both drying and granulation processes, adapting to varying production needs. |
| Precision and Control | Allows for precise control over particle size, distribution, coating thickness, and other product parameters. |
| Enhanced Product Quality | Results in uniform and controlled granules with improved characteristics, crucial for pharmaceutical products. |
| Scale-up Potential | Scalable from lab-scale to commercial production, maintaining consistent product quality and performance. |
This technical guide aimed to provide a thorough understanding of fluidized bed granulators, from their fundamental principles to practical applications and challenges.
Fluidized bed granulation stands as a versatile and indispensable technique for industries requiring precise control over particle characteristics and efficient manufacturing processes.
| Technical Specifications | |||||||||
| MODEL | FBD-15 | FBD-30 | FBD-60 | FBD-120 | FBD-200 | FBD-300 | FBD-400 | FBD-500 | FBD-600 |
| Container Gross Volume Ltr. | 46 | 71 | 142 | 280 | 475 | 650 | 870 | 1055 | 1350 |
| Max. Batch Capacity (0.5 bd) kg* | O to 15 | 20 to 30 | 40 to 60 | 80 to 120 | 160 to 200 | 200 to 300 | 300 to 400 | 400 to 500 | 500 to 600 |
| Blower Motor HP** | 7.5 | 7.5 | 10 | 20 | 25 | 30 | 40 | 50 | 50 |
| Air Flow (CFM)± 10 % | 430 | 706 | 1060 | 1880 | 2590 | 3235 | 3825 | 4000 | 4705 |
| Steam Pressure (kg/cm2) | 3.5 | ||||||||
| Steam Consumption (kg/hr) | 30 | 50 | 80 | 140 | 216 | 250 | 288 | 344 | 384 |
| Electric Heater (kW) | 18 | 20 | 36 | 60 | N.A. | N.A. | N.A. | N.A. | N.A. |
| Compressed Air Pressure (bar) | 8 | ||||||||
| Drying Temp (°C) | 35-80 | ||||||||
| Electrical Supply** | 415 V±10%,AC,3 ∅,50 Hz | ||||||||
We offer best in class Fluid Bed Dryer machine which is smartly designed and made with stainless steel grade 316 which provides better resistance against chlorides, corrosion and chemicals. Profound research about the industry has shown that machine suitable for various sectors are the key for production growth, hence the fluid bed dryer machine is made in such a manner that it can work flexibly across various sectors of industry like chemical, pharmaceuticals, dye manufacturing, food industry etcetera. The machine is capable for materials of various shapes like granular and coarse. Formerly tray dryers were used to consume 5 to 6 hours for the process, while the new fluid dryer machine performs the same process in 30 to 35 minutes of time with easiest modes of operation.
Working Structure:
The base of the container is filled with material and a hot stream of air passes through the chamber, due to this fluidization takes place in the chamber and it develops ideal conditions for the material to dry quickly. Solid particles move in the product chamber when material bed is expanded by air stream at ideal velocity. Machine works in organized way to transfer heat to each solid particle so that drying process is perfect and organized. Fluid bed dryer machine is equipped with filter bags in order to avoid any sort of spillage of particles from the machine during the process of fluidization. Latest technology of passing the hot air in the container is used in such a manner that there is no loss of energy in form of heat. Machine is designed in such a manner that fluidization process generates perturbation of material (solid particles) and heat is transferred as each particle is surrounded by stream of hot air.
Select your Industry specific model:
- Fluid bed dryer machine are available in a wide range. – (5 kg to 500 kg)
- Industry and requirement specific pressure gauge to keep an eye on pressure dropping.
- Accurate air monitoring facility by using air control damper.
- Automated system and with timer facility.
- Gasket technology used instead of cylinder to provide hassle free experience.
- Key areas upgraded with unit of fan motor.
- Latest technology silence to provide negligible noise during production.
- User friendly operations equipped with devices like key board and printer.
- Damaged finger bag can be tracked easily due to technology of monitoring flow chart. (It is one of the premium features included in our model of fluid bed dryer)
- Silicon rubber tube filled with air is used to provide PP finger bag.
- Good manufacturing practices (GMP) norms & guidelines completely followed to provide standard quality machines.
- Bottom section is available above the level of ground with bucket type shape.
Benefits & Advantages:
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