Fluid bed equipment is a vital component in various industries, particularly in pharmaceutical and chemical sectors. This article provides a comprehensive overview of fluid bed equipment, its types, working principles, advancements, and applications. It explores how this technology is revolutionizing material processing, drying, granulation, and coating processes, enhancing efficiency and product quality across industries.
Introduction: Fluid bed equipment has gained significant importance in modern industries due to its versatile applications in various processes such as drying, granulation, coating, and particle formation. It involves suspending particles within an upward-moving gas stream, creating a fluidized state that promotes efficient heat and mass transfer. This article delves into the technical aspects of fluid bed equipment, highlighting its evolution, working principles, recent advancements, and real-world applications.
Constructed to withstand an operational pressure of 2 Bar at 80 degrees Celsius, our Fluid Bed Dryers (FBDs) exhibit an elevated drying efficiency of 18 – 20%.
This translates into reduced drying durations and the establishment of consistent fluidization patterns.
Our Air Handling System is meticulously engineered to ensure the even dispersion of heat throughout the material slated for drying, facilitating the necessary latent heat contribution for moisture evaporation.
Working Principles: Fluid bed equipment operates on the principle of fluidization, wherein a gas (usually air) flows upward through a permeable bed of particles, causing them to become suspended and act like a fluid. This fluidized state increases inter-particle contact and facilitates uniform heat transfer, making it an ideal process for various applications.
Types of Fluid Bed Equipment:
- Fluidized Bed Dryers: These are widely used in industries for drying solid materials. The fluidization process ensures even drying and prevents product agglomeration.
- Fluidized Bed Granulators: In the pharmaceutical industry, fluid bed granulators are employed for the production of granules from powders. The fluidized state aids in controlled agglomeration and particle size distribution.
- Fluidized Bed Coaters: Coating processes, such as film and sugar coating in pharmaceuticals, benefit from fluid bed coaters. The uniform coating achieved due to fluidization enhances product quality and performance.
Advancements in Fluid Bed Equipment: Fluid bed technology has undergone substantial advancements to improve efficiency and meet industry demands:
- Control Systems: Modern fluid bed equipment incorporates advanced control systems that monitor and regulate parameters such as temperature, airflow, and pressure. This enhances process control, leading to consistent product quality.
- Multi-Functional Units: Recent designs allow a single fluid bed system to perform multiple processes such as drying, granulation, and coating, reducing the need for multiple pieces of equipment and saving space.
- Enhanced Heat Transfer Mechanisms: Innovations in nozzle designs, bed geometries, and fluidization techniques have led to improved heat transfer rates, reducing processing times and energy consumption.
- Integrated Process Analytical Technology (PAT): Integration of PAT tools like in-line particle size analysers and moisture sensors enables real-time monitoring and control of the process, ensuring product uniformity and quality.
Applications of Fluid Bed Equipment:
- Pharmaceutical Industry: Fluid bed technology plays a pivotal role in the pharmaceutical sector. It is used for drying active pharmaceutical ingredients (APIs), granulating powders, coating tablets, and producing controlled-release formulations.
- Chemical Industry: Fluid bed equipment finds applications in chemical industries for drying and cooling of chemical compounds, catalyst production, and manufacturing of specialty chemicals.
- Food Processing: In the food industry, fluid bed equipment is used for drying and roasting coffee beans, nuts, and grains, as well as for coating snack products with Flavors and colours.
- Agrochemicals: Granulation of fertilizers, pesticides, and herbicides benefits from fluid bed technology, ensuring uniform distribution and controlled release of active ingredients.
- Environmental Applications: Fluid bed systems are employed in waste-to-energy plants for incineration and combustion processes, aiding in reducing the volume of waste materials.
Challenges and Future Prospects: While fluid bed technology offers numerous advantages, challenges such as particle attrition, bed stability, and consistent fluidization still persist. Researchers are actively exploring ways to mitigate these issues through advanced materials, improved designs, and enhanced process control algorithms. The future holds promise for more efficient and versatile fluid bed equipment that can cater to evolving industry requirements.
Certainly, here is an example of a technical specification table for a Fluid Bed Dryer, showcasing key parameters and specifications:
| Parameter | Specification |
| Equipment Type | Fluid Bed Dryer |
| Operating Principle | Fluidization of particles in an upward gas flow |
| Capacity | 100 kg/h (example) |
| Material of Construction | Stainless Steel 316L |
| Heating Source | Electric/Steam/Hot Air |
| Airflow Rate | 300 – 800 m³/h |
| Temperature Range | Ambient to 150°C (adjustable) |
| Bed Dimensions (L x W) | 1.2 m x 0.8 m (example) |
| Bed Area | 0.96 m² |
| Particle Size Range | 50 µm – 5 mm |
| Inlet Air Filtration | HEPA Filters |
| Exhaust Air Filtration | Baghouse Filter or Cyclone Separator |
| Control System | PLC-based with Touchscreen Interface |
| Process Monitoring | In-line Particle Size Analyzer |
| Temperature and Pressure Sensors | |
| Moisture Sensor | |
| Safety Features | Explosion Venting System |
| Over-temperature Protection | |
| Emergency Stop Button | |
| Interlocking Door Mechanism | |
| Cleaning and Maintenance | CIP (Clean-in-Place) System |
| Removable Bed Grate for Easy Cleaning | |
| Energy Consumption | 25 – 40 kW (depending on load and process) |
| Application Areas | Pharmaceutical Drying |
| Food Processing | |
| Chemical Industry | |
| Agrochemicals |
Please note that the specifications provided above are for illustrative purposes only and should be adapted to match the actual specifications of the fluid bed dryer model you are referencing.
The table can be expanded or modified based on the specific features and technical details of the equipment.
Conclusion: Fluid bed equipment has become an integral part of various industries, revolutionizing processes like drying, granulation, coating, and particle formation. Its ability to create a fluidized state of particles has led to enhanced heat and mass transfer, resulting in improved product quality, efficiency, and reduced energy consumption. With ongoing advancements and a growing understanding of its applications, fluid bed technology is poised to play an even more significant role in shaping the future of material processing across diverse industries.
Overall, the global demand for industrial machinery remains robust due to the continuous evolution of technology, changing consumer needs, and the growth of various industries. Manufacturers are focusing on innovation, efficiency, and sustainability to meet the diverse demands of a rapidly changing global market.
The shift towards automation and Industry 4.0 concepts has led to increased demand for advanced manufacturing machinery, including CNC machines, robotics, and 3D printing equipment. These technologies improve efficiency,
Comply with following regulations:
- FDA standard compliance
- CE compliance
- cGMP compliance
- 21 CFR Part 11 software
| 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:
We are well known machine dealers, traders, manufacturers and suppliers. Get best quotation for your specific model of fluid bed dryer and avail special benefits. Visit us right now and choose an ideal machine for your business model. Our specialized team is ready to serve your demands as we help you to achieve desired industrial production goals.
Automatic Tablet Coater- Film & Sugar Coating
Application:
The SHREE BHAGWATI’s advanced tablet coating machine is a high-efficiency, energy-saving, and safe equipment for film and sugar coating of pharmaceutical and food products. It features mechatronics technology, meets cGMP requirements, and supports aqueous and non-aqueous coatings, including enteric and non-enteric film coatings. It’s a versatile solution that ensures optimal productivity and exceptional product quality.
Process:
The tablet undergoes a continuous and intricate orbital motion within a closed rotating drum, guided by a streamlined arrangement of baffles. As per the predetermined technological process and optimal parameters, the coating medium is automatically sprayed onto the tablets. Simultaneously, hot filtered air is supplied under negative pressure.
This heated air permeates through the layers of the tablet, effectively drying the sprayed coating medium uniformly. Consequently, a solid and smooth surface film is formed, resulting in a high-quality coated tablet. The entire process is seamlessly controlled by an advanced PLC system, featuring a user-friendly touch screen interface.
Drum Geometry:
- Compact design, allowing for efficient use of space.
- Large spray area with a high number of nozzles, ensuring comprehensive coverage during the coating process.
- Rapid and effective mixing of the tablets, both horizontally and vertically, for consistent and uniform coating.
- Easy and thorough cleaning facilitated by dedicated cleaning nozzles, saving time and ensuring hygiene.
Mixing Elements:
- Leveraging years of expertise in mixing technology, SHREE BHAGWATI has introduced highly efficient mixing baffles for their Coater. These innovative baffles are designed for easy cleaning and enable a remarkable filling level flexibility, ranging from approximately 20% to 100% of the working volume. This means that the coating drum does not need to be replaced when adjusting the filling level, while ensuring gentle handling of the product.
- When the coater drum runs in reverse, all tablets are swiftly and completely discharged through a dedicated opening on the front door of the coater. This seamless process is facilitated by special discharge elements, eliminating the need for any additional discharge aids.
Nozzle Arm:
- The Coater incorporates a specially designed nozzle arm that offers adjustable positioning on two pivot axes, which can be motor-driven if desired. This unique mechanism allows for an extensive range of nozzle adjustments, effectively utilizing the 20-100% filling level variability. As a result, various batch sizes can be produced without the need for drum changes.
- The Coater is equipped with an optimal number of nozzles, ensuring an ideal spray pattern and maximum coverage across the entire spray area. The coating solution is uniformly applied, resulting in consistent coating quality.
- Depending on the pump version, the fluids can be delivered to the nozzles either through a single line or through individual lines for each nozzle, allowing for flexible configuration.
- For enhanced precision and control, an optional laser measuring technology can be utilized to measure the position of the nozzles. This feature enables reproducibility and even the ability to control the exact positioning of the nozzles for precise coating application.
Salient Features
- Designed in compliance with cGMP standards, featuring product contact parts made of AISI 316 stainless steel.
- Capable of film and sugar coating for tablets using aqueous, non-aqueous, enteric, and non-enteric solutions.
- Equipped with a variable speed drive through VFD for the perforated pan, ensuring flexibility in operation. The machine has a sturdy structure with a wash sink, air plenum, and front and side doors.
- Advanced PLC controls with an intuitive HMI touch screen interface for seamless operation.
- Incorporates baffles for excellent mixing and tumbling performance.
- Includes a spray system with a peristaltic pump, atomized spray gun, and solution tank for efficient coating application.
- Features an inlet air handler with pre-filter, blower, dehumidify coil, heat exchanger, final filter, and HEPA filter for clean air supply.
- Equipped with an exhaust air blower and scrubber to effectively eliminate air pollution. Tablet discharging is facilitated through a special diverter assembly integrated with the CIP/WIP system for easy cleaning.
- Designed with explosion-proof construction for enhanced safety.
- Provides provision for adjusting the angle of the spray gun as per requirements.
Safety Features
- Nozzle/Spray arm close interlocking.
- Temperature control based on PID control using PLC control logic.
- Dampers open/close feedback using proximity sensor.