YC-1000 Laboratory Granulator (fluid bed)
- One machine can be used for spray drying, spray granulation and spray coating.
- Spray drying is a low temperature type, suitable for spray drying of traditional Chinese medicine & natural product extracts, which has no wall sticking.
- Spray granulation is suitable for granulation of sugary materials, with the new backflushing system, high material yield.
- Suitable for coating of small granular materials, uniform coating.
Pilotech Laboratory Granulator (fluid bed)
YC-1000 laboratory spray granulator integrates spray drying and fluid bed granulation function.
One machine realizes the functions of two machines, which can save the experimental site and expense.
It is an innovative product of spray granulation.
- Data Sheet
|Sr.no||Parameter||Pilotech YC-1000 spray granulator|
|Function||Spray dryer,spray granulator,coating,mixing|
|4||Spray granulator capacity||Max. 1000g/batch|
|Spray dryer capacity||Max. 1500ml/h|
|5||Minimum sample volume||50g|
|Spray dryer inlet temp.||105-200⁰C|
|7||Compressed air||2-4 Bar|
|13||Nozzle type||Two fluid nozzle|
|14||Nozzle jet||0.7mm standard/(0.5/0.75/1.0/1.5/2.0mm available)|
|16||Peristaltic pump||Max. 1500ml/h|
|19||Main chamber volume||10L|
|22||Main chamber material||SUS304 Stainless steel &High borosilicate glass|
|23||Body material||SUS304 Stainless steel|
|24||Seal of cyclone/cylinder||Silicone|
|30||Display||7-Inch LCD display for Heat, Spray, Pump, Air pressure, de-blocker frequency|
Laboratory Granulator (fluid bed)
YC-1000 laboratory spray granulator integrates spray drying and fluid bed granulation function. One machine realizes the functions of two machines, which can save the experimental site and expense. It is an innovative product of spray granulation.
Lab granulator has been produced in our company since 2005. Over 15 years of producing experience, there are more than 2,000 clients worldwide using our lab granulators.
Pilotech YC-1000 lab granulator is a kind of spray granulator, or you can call it fluidized bed granulator. It has two granulation modes:
1) The sample is mainly composed of liquid and transported to the spray head by a peristaltic pump. The sample is evenly sprayed over the granulation chamber under the effect of compressed air. And base materials such as fluidized dextrin, etc. are placed in the granulation chamber in advance. Thereby centering base materials, atomized samples are caked on the base materials to be granulated into required particles;
2) The sample is in the form of small particles and placed in the cavity of fluidized bed in advance. It’s fluidized due to hot air. The binder is atomized to form a bridge between small particles. So these small particles are gradually caked and granulated into the required particles ranging from 200μm to 5mm.
Pilotech YC-1000 lab granulator has multiple specifications, including 300g/ batch, 500g/ batch, 1000g/ batch, 3000g/ batch, and 5000g/ batch.
Frame of the Pilotech lab granulator is made of SUS304 stainless steel. Major parts are from international famous brands. The granulating chamber is made of SUS304 stainless steel and high borosilicate glass. It’s durable and used for observing the whole experiment.
Top spray and bottom spray are designed for our lab granulator, of which, the top spray is used for fluidized-bed granulation, while the bottom spray for fluidized-bed coating. Side spray (tangent spray) is also designed for the 3KG and 5KG granulators.
Spray drying function is also added for the 1KG lab granulator. This way, you don’t need to buy a lab spray dryer for drying sample.
Pilotech YC-1000 lab granulator adopts touch screen with a PLC control mode. Both the operating interface and operation manual are in English. At the same time, we also provide a video to demonstrate every operating step in details, as if an engineer is by your side. Letting you know how to operate and make the full use of the lab granulator.
If you want know more about YC-1000 lab granulator, Please feel free to ask us catalog & a quick quote now.
PILOTECH LAB GRANULATOR: ALL YOU NEED TO KNOW
The last few decades have been about records of successes from one innovation to another. Different industries are in the business of deploying technology to make corporate works, processes, and mechanisms seamless and effortless. Interestingly, there have been overlaps in the different fields in terms of how these technologies are used to bring about similar and also different results.
The spray granulation process is one of those incredible inventions of the last half of a century, or so. Pilotech is one firm that has contributed immensely to this area. Annually, Pilotech is responsible for the production of thousands of tons of LAB GRANULATORs for the chemical and allied industries. This equipment which has been patterned into different models is being used in the production of customer-specific and tailor-made spray granulates and powders on fluidized bed LAB GRANULATOR or spray dryers.
Through the spray granulation systems, the company continues to equip and empower a wide range of sectors and subsectors of the chemical industry with quite a number of its products all over the place. These include construction chemicals, fluid bed processor, specialty chemicals, cleaning agents, animal feed, detergents, etc.
History of Pilotech LAB GRANULATOR Production
Pilotech leads the park when it comes to deploying spray granulation process to build a robust industry. There is a lot of history, trusted experienced, tested expertise, and quality assurance team behind the success of this conglomerate. Suffice to say that Pilotech has been responsible for the production of a number of chemical equipment, including lab granulator, fluid bed coater, fluid bed processor, fluid bed dryer granulator, etc. Besides, Pilotech produces mini spray dryers, multi-function, multi-feature extracting tanks, world-class high temperature sterilizers, among others.
These products come at a budget that doesn’t require users to break the bank. In addition, laboratory spray dryers from are easy to maintain and operated. Plus, there is long life expectancy and durability that comes with them. No wonder, the company’s products are the most reviewed by researchers. Pilotech stands tall above other competitors in the industry, and its effort has proved right, given that it has taken well over 70% of the Chinese market. Plus, it has a high exportation and acceptability rate in more than 60 countries, including the USA, Canada, and the UK.
This Shanghai-based technology company has been around for over two decades, leading the industry in solution delivery when it comes to production of lab equipment. With a top-of-the-line Research and Development team that ranks top and is popular for spinning out high and low-end products, Pilotech ensures incredible internal and external quality control checks. Needless to say that the company has a strong global partnership, client and user that runs in their thousands. On top of that, Pilotech state-of-the-art technology institutes, research centres, as well as reverse engineering sections.
Spray Granulation Process
Spray granulation is refers to a phenomenon wherein a fluidic compound dehydrates over an active element. The new shape that’s formed is much thicker, harder, with many particles that contain unique properties. You can re-spray the particles all over again, to form pellets in circular shapes. Spray granulation also brings about cohesive layers of circular pellets.
Interestingly, the spray granulation process is one of the important processes used in the field of drying and particle shaping. Apart from spray-drying liquid or solid, these agents also are made to go through the rigours of spray granulation (whether bottom spray or top spray), spray solidification, fluid bed coating, fluid bed drying, and a host of other systems and subsystems. In the final analysis, the end particles or powder often come out free-flowing, compact, firmly structured, dust-free, finely granulated, and enveloped in several layers. These layers, as it were, also undergo the spray drying process wherein the fine particles that have been crushed into their liquid form in a fluidized bed could also be spray solidified. By that we mean, the particles can be spray-chilled or cooled.
Types of Granulators
There are various specific forms of granulators on the market. Every growing sector has additional choices to select the type of granulator it requires. Let us look at some of these sophisticated and wellutilized granulators.
High-Speed Mixing Granulator
This granulator comes with excellent efficiency; it can mix up various powder components to granules, in a single process. The high speed mixing granulator is mostly used by the food industry, medical industry and the chemical industry. It blends adhesives with the powdered components in the mixture chamber, before moving them through the cutting process to produce homogeneous granules.
The dry granulator, with the use of the crystallized water in the substance, transforms the pellets of powder to granules. This highly advanced machine comes with a sturdy structure, a novel, perfect durability and functionality. The granules produced by the dry granulator are clasped into pellets and capsules. This granulator is commonly used by the pharmaceutical industry, food industry, chemical industry and other industries applicable. It is strictly used for granulating substances and isn’t appropriate for the wet granulation technique.
This is another type of granulator that is utilized in the food and pharmaceutical industries. They are used to produce granules in different variations, from congregate materials. One aspect of this machine is providing block products for further disintegration to other mixtures and composite. The interchanging handle that comes with the reciprocating granulator is equipped with paddles made of poly-ethene, brushes or beaters. The machine beats against the immobile outlined screen, which measures the final output per the fitted gaps, through the cutting process, to form homogeneous granules.
This granulator is another exceptional product suitable for the food, chemical, pharmaceutical and other related industries. It is ideal for viscous materials. Its steady operation ensures that the granules are well prepared for the drying process. The granulator can be easily maintained and cleaned due to the stainless steel framework. It can also be easily operated.
The high-speed granulator works with a turning knife that operates, in contrast with the fixed screen that has the right gap proportion. Particles whose proportion is smaller than the screen, goes through to discharge, while the more significant proportions are decreased.
Some of the significant types of Granulation Technique
Pneumatic Dry Granulation
It is a dry translation technique that makes use of a rolling compactor, and a classified air technique for the production of granules that will be compressible and flowable. This technique involves the creation of granules from powdered particles through the application of the compatible power of the rolling compactor. The end result is a blend of granules and finely made particles. The tiny granules are singled out from the granules with the expected size, then the granules with the likely sizes are put into a fractionating chamber, from there, they are designed into pellets.
Reverse Wet Granulation
The reverse wet granulation is a wet granulation technique; it is a technique that entails the submersion of dried powdered content into a binder fluid, with a controllable disintegrating system to produce granules. The dried powder is put into the binding liquid and undergoes mixing in the granulator. Secondly, the drug can be immersed into a hydrophilic polymer solvent to create a granulating fluid in the form of a drug-polymer. To produce granules, other adhesive substances are added to the drug-polymer. The wet granules that are produced are dried, after which they are milled. The types of granules produced using this technique, had an excellent flowability nature, just like the results of the wet granulation application.
This technique involves the use of steam as a binder, in place of the usual binder fluid. The pure state of steam can create a high percentage of dispersion into the powder, and also provides a better thermal situation, when the drying process begins. When the steam is condensed, a flat hot film appears on the powder elements; it needs an amount of homogeneous particle for dispersion. It does not require the drying process.
This granulation technique has to do with spraying a small amount of liquid over liquefied nitrogen. The liquid sprayed over the nitrogen instantly freezes to pellets. During the freeze-drying procedure, a sublimation-ice process is used to dry the pellets with no effects of separation. The final product of this procedure is the circular pellets with flowability. They are formed using water and solvent established slurries.
This technique involves the application of a fluid-binder as foam, unlike the other processes that include the addition of liquid and spraying on the powder elements. The foam binding solution helps in avoiding issues such as inconsistency and uncertain binder dispersion that could intentionally affect the density of the tablet and shape of the tablet.
Fluidized LAB GRANULATORs
All forms of fluidized spray are mostly applicable in a fluid bed. The fluid bed granules are similar. The powder mixture is sprayed uniformly with the liquid compound. The pellets formed can be influenced in various ways, due to the different parameters in place. Fluidized LAB GRANULATORs form particles that are affected by multiple factors which are:
- Solid with moisture content
- Flowability in liquid spray
- Level of airflow
- Pressure of atomization
- Batch Fluid Bed
Granulations that have batch procedures involve placing the first dry product into the product compartment. It then undergoes an intensive mixture in the thermal gas flow; it is suspended and collected by using an adequate bonding agent to spray. When using the required parameters and high thermal conduction, the product is then dried to the proper moisture volume.
Continuous Fluid Bed
The continuous granulators are broken down into different divisions that work with different timing, velocity and conditions. For example, granulation is applicable in the first and second category, drying is suitable in the third category, while cooling is the last category in the chamber procedure.
Applications of Granulation
Advancement in technology and inter-industry relationship contributes to the application of granulation technology into several industries.
Spray granulation helps in enhancing powder flowability and mechanical features of a pellet. In this way, granules are obtained by adding liquid binders and liquid solutions. When the granulating fluid is in excess quantity, thinner particle sizes and dense granules are produced. There are differences from each batch are minimal, due to the maximum liquid quantity needed to produce the provided particle size.
Granulation techniques like wet granulation, are used to provide uniformity, flowability, compatibility and stability of the solid-state of the drug. The granulation liquid quantity determines the granules particle size. Granulation involves the combination of small particles to produce larger cohesive particles. The importance of particle sizes is essential, they shouldn’t be too big or too little, as this can affect the flowability and the density of the granules.
Many processes are utilized in controlling a granulator. The fractionating chamber, feed level, liquid binder, all these play their roles in affecting the particle size. The particle size is measured simultaneously by the sensor; this is to help monitor the process of granulation.
Granulators are mainly utilized in producing materials in specific industries like the food, chemical and pharmaceutical industries. It modifies light elements in powdered forms, to dense like granules with flowability. Granulators are used in the following industries: pharmaceuticals (to produce animal drugs), Food (for the production of sweeteners, soup ingredients, and soya sauce), Beverage (to produce cocoa, tea), Chemical (organic acid, detergent).
An Overview of Pilotechs LAB GRANULATOR Models
Pilotech LAB GRANULATOR is fashioned into a variety of models, each made for different purposes. Interestingly, each model is made to function differently, except for the general functions which unite them as LAB GRANULATOR.
As earlier identified, Pilotech models these equipment based on the specific requirements of the customer and the need of each chemical industry. Hence, production is informed by need and emerging trends.
Pilotech’s spray granulations makes use of other sub-processes, including spray drying granulation, coating design and drying of the fluid bed. Spray drying with low temperature is also utilized. Each of the different models is intended to serve these process needs.
YC-1000 Mini LAB GRANULATOR
As the name suggests, the Pilotech’s mini LAB GRANULATOR is a top-quality product sought-after for its incredible features and practical functions. Built with a sturdy and solid material, this piece guarantees unparalleled durability, giving confidence for a long lifespan.
What’s more, the product is space-efficient, multi-functional, budget-friendly, and offers great value for money. Plus, with more than 1500 users in over 60 countries, the Pilotech’s mini LAB GRANULATOR also features granulation, fluidized bed drying and coating, as well as spray drying. It is great compact, flexibble design
YC-310 Lab Scale Fluid Bed Dryer
This LAB GRANULATOR from Pilotech is best for lessened material quantities that need the right temperature within the required time frame—particles with sizes as small as 5 microns can be processed using this machine. The speed flow makes the thermal efficiency splendid. Plus, this adds to increased drying capacity as well as high rapid drying rate.
YC1000 Laboratory Granulator
It is a fluidized bed LAB GRANULATOR. This machine possesses multi-functions of spray coating, fluidized bed drying and spray drying. Minimal temperature is enabled for spray drying. It is suitable for processing materials with heat intensity and sweeteners.
YC-03 Fluid Bed Processor
This fluidized bed granulation coating machine has a batch capacity of 3kg and 5kg, respectively. The YC03 fluid bed processor is made up of three sections, the top spray, bottom spray, and side spray. When it comes to dealing with particles of different variations, this machine is the best bet. It also comes with a triple-level purification blower.
Working Mechanism of Fluidized-Bed LAB GRANULATOR
The fluidized bed LAB GRANULATOR is mainly used in the pharmaceutical industry. It is utility equipment; the granulation drying and mixing process are all done using the same machine. Most of the essential parts that make up the fluidized bed LAB GRANULATOR come in various design functions. The ones that are in line with the direction of fluidized gas flow are the gas inlet chamber that serves as the inlet that receives fluidized air; the Gas dispersion, product compartment, an extended chamber that has bag filters in the enlarged chamber, and the 4-nozzle structure.
The four-nozzle structured binder spray pattern which include the Pressure Nozzle that helps in the disintegration of pressurized fluid due to its atmospheric unstableness and effect. There is the Rotation Nozzle or otherwise called ‘rotating atomizer” used only for dry spraying. We also have the Unaired Nozzle. This is a nozzle that divides the fluid into dual streamlets that later merge at the opening of the nozzle, where the breach results in drops. The last is the Atomized Gas Nozzle, which is a dual fluid nozzle. One of the fluids, which is the binding solvent, is atomized via air compression to produce the second fluid. It is well known for the use of fluidized bed spray granulation.
FEATURES OF PILOTECHS FLUIDIZED BED LAB GRANULATOR (YC-1000 Lab Granulator)
Pilotechs fluidized LAB GRANULATOR come with a lot of amazing features and components that make it a stand-out and sought-after product in the market. Let us examine the features of Pilotech’s YC-1000 Laboratory Granulator.
- Power: 5KW, 220V, 50/60Hz
- Maximum capacity: 1500ml/h
- Temperature: 40-150o C
- Mixing/Coating: 50-100g
- Nozzle Type/Jet: 2-fluid nozzle/0.7mm standard
- Airflow: 0-150m3/h
- Screen: 7-inch LCD display
- Material construction: stainless steel
Key Features of the YC-1000 Fluid Bed Lab Granulator
The Pilotech’s YC-1000 Fluid Bed laboratory LAB GRANULATOR is an innovative device that blends spray granulation with spray drying, making it also functional in the area of uniform coating. It means users don’t have to buy spray dryer when they need to dry samples.
Typically, this model can be used to spray granulate materials that are in sugary form, thanks to its high material build and back-flushing system. For uniform coating, this model is perfect for granular materials.
The Pilotech YC-1000 equipment also comes with a colourful LCD touch display with a PLC regulation mode to show parameters ranging from, pump speed, the frequency of the fan, drying chamber pressure, and the chamber temperature.
This display is user-friendly with easy-to-understand English manual and operating interface. Plus, Pilotech offers video to help during installation and operation of the fluidized lab LAB GRANULATOR machine. The interface accurately displays the vacuum levels and temperature degree.
Top of Form
Bottom of Form
Dual granulation patterns
The YC-1000 boasts two incredible granulation models. One is that the fluid inside the machine is conveyed through the aid of the peristaltic hose to the spray head. The sample of the liquid that is sprayed gets to the granulation chamber and is shared evenly, thanks to the influence of the compressed air. The system ensures that the granulation chamber receives the fluidized base materials promptly so as to ensure proper caking and highly granulated particles.
The second mode of granulation consists of the tiny particles promptly positioned in the hollow of the fluidized bed. The hot air enhances the rate at which the small particles are fluidized. The small particles are linked by the atomized binder. Depending on the needs of the user, the particles can be crushed into different sizes with a between 200μm to 5mm
Three Spray Modes
The YC-1000 LAB GRANULATOR is designed for the two common spray systems, the top, bottom, and side spray models. The top spray is perfect for fluidized bed granulation; the bottom spray system serves the bed coating purpose, while the side system is designed for the 3KG and 5KG granulators.
Sturdy Steel Build
The Pilotech YC-1000 LAB GRANULATOR boasts a frame made from the stainless steel of the SUS304 standard, making it highly resistant to corrosion and rust. The granulating chamber of the machine is also made of the same material with added high borosilicate glass that ensures durability and expanded life expectancy.
APPLICATION OF FLUID BED LAB GRANULATORS
LAB GRANULATOR works via fluid bed spray systems, and these work in various ways, depending on the position of the spray systems. The fluid bed system is made up of three distinguishable spray systems:
- Top spray system
- Bottom spray system
- Side spray system
The Top Spray System
The entire top spray system process requires that you start by charging all the substances into the process chamber. This is followed by a fluidizing procedure, involving compressing air to cause material suspension. There is the spraying procedure from the top that is done by making use of the atomized gas nozzle to spray the binding solvent downward. This process also requires material drying, stopping the fluidization procedure, before the final step which is product discharge.
The Purpose of a Top Spray System in a Fluid Bed Granulator
Fluid bed procedures can carry out various tasks, but it all relies on where the spraying system is located. So according to due process, the top spray system is applicable for the following:
- Drying the mixture of wet powder and granules
- For Granulation
- For coating
Drying the Mixture of Wet Powder and Granules
Fluid bed processors are mostly seen in coating and granulation equipment. It is because where the nozzles are located doesn’t affect the way it functions. The following are the working procedures of a fluid bed dryer granulator:
Hot air is released from the rear section of the system. Suspension of materials slated for drying occurs, due to the rise in air velocity caused by an ascending pulling force. In the lab fluid bed dryer, surrounding air blows into the heaters. As the moisturized particles absorb receive air, the moisture is extracted, producing a dry, free material. The air passing out of the fluid bed dryer goes through the filter, recovers bits of particles from the drying process.
The granulation and drying procedure can be done in one machine. It is why the top spray system is utilized in mainly fluid bed granulators. It is because of the rate of effectiveness and consistency.
Though the top spray process may be simple, the applications are limited. Therefore top spray coating is not applicable where density, comparability and quality of the film are the watchwords. The top spray coating is mostly suitable in chemical and food industries.
The Bottom Spray System
This spraying system is carried out from the bottom. The hot air in the machine blows the granules and powdered particles from the bottom, in an upward direction. The nozzles at the bottom spray these substances uniformly as they move up. The bottom spray system process is mostly used in the pharmaceutical industry, for the coating of pellets and powder. You can achieve excellent quality and uniformity utilizing this system. These features are synonymous with the bottom spray system:
- Underneath the fluidization chamber lies the position of the spraying nozzle
- The dry spraying is reduced because the distance between the particles and the nozzles are limited
- Coating quality and homogeneity is high
Side Spray System
The technology this one is made of is a bit different from the top and bottom spray systems. Here are some of the unique attributes of the side spray system. The nozzle is situated beside the product compartment. It comes with a changeable spinning disc. Different types of force are applicable when the machine is active: levitating force (lifting), centrifugal force and gravitational force.
The centrifugal force can be controlled by predicting the speed of the disc, and the velocity in the air, because it is the volume of air and the velocity that raised the particles. It can be done by comparing the disk space. This spray system is a bit more diverse than the rest.
CHOOSING FLUIDIZED LAB GRANULATORS: WHAT TO LOOK FOR
Purchasing a new fluidized LAB GRANULATOR won’t come easy. High cost and complexity need to be considered carefully and appropriately researched, before going in for a purchase. One of the main things that should come to mind is a machine that will meet your demands. So what do you need to know to choose the right fluidized LAB GRANULATOR?
- Multiple Features
With the multiple choices available, how do you narrow your search? First of all, find out the appropriate features that are essential for whichever industry you choose. Consider the expenses, type of business, and what goals you want to achieve.
- Multi-Purpose Functions
A lot of fluidized LAB GRANULATORs have multiple applications in one system. Though you might not need these numerous functions, they’ll be of assistance to you in the nearest future. It will save you expenses. Instead of purchasing three different machines with different features, isn’t it better to buy one that has the capacity of the three? As you can see, it’s simple logic.
- Special Features
Always look-out for special features that will help in the efficiency of your process time. It is essential to search for distinctive features during your research. Examples of these unique features are the agitator system, liquid delivery manifold, expansion chamber etc.
- Expert Advice
You can enlist the help of experts to help you out in making the right decision, to ensure that the machine of your choice is suitable for your business. Look for credible suppliers who can help you in this process. I would recommend you choose Pilotech, because of their impeccable track record. They have the right fluid bed granulator manufacturer that will give you any modification that you require.
PILOTECH AFTER-SALE SERVICES ON FLUIDIZED LAB GRANULATORS
Pilotech provides excellent after-sale service for customers, upon purchase of their products, ranging from milk spray drying machine, Herb drying machine, lab drying machine, Pilotech mini spray dryer, spray dryer machine, YC-015 spray dryer, lab spray dryer, mini spray dryer and more.
Pilotech provides customers with all support and information they need before, during and after the purchase of the LAB GRANULATOR, and indeed all their products.
Instalment & Maintenance
Upon purchase of a Pilotech product of your choice, Pilotech has credible engineers and technicians at your disposal, to help with the installation of your machine. Not only that, should any technical issues arise when making use of the products, but Pilotech engineers are also always at your service 24/7.
Onboarding and Training
This is an essential aspect of Pilotech’s aftercare services. Pilotech understands that most of their products come with sophisticated features that customers might find confusing. Fear not, Pilotech is here for you. When you purchase Pilotech products, individual training sections are organized for customers to be able to get acquainted with the product functions, features and operation guidelines.
Customer service agents are on standby 24/7, to cater for all your needs, inquiries and even suggestions. So whenever you have an issue or query regarding a Pilotech product, feel free to call the following numbers or contact via email.
Pilotech offers all its esteemed customers a one year warranty on all purchased products. Free services are also provided during this period, but only of the damages are not human inflicted.
Frequently Asked Questions (FAQ)
What is Spray Granulation?
Spray granulation refers to a a fluidic compound dehydrates over an active element.
What are the uses of a LAB GRANULATOR?
LAB GRANULATORs are used by pharmaceutical, chemical and food production industries for creating materials like soya sauce, drugs, beverages, detergents etc.
How do LAB GRANULATORs work?
They work through the fluid bed spray system, which is made up of the: The top spray system, the bottom spray system and the side spray system.
Which LAB GRANULATOR Brand can you recommend?
I would recommend you go for Pilotech LAB GRANULATORs, due to popularity as renowned LAB GRANULATOR producers in the world today.
What type of LAB GRANULATORs do they produce?
Pilotech is home to a wide variety of products and technologies. Its team of expert technicians, engineers, market and business developers are behind the top-of-the-line produces, including the laboratory LAB GRANULATOR, the laboratory low-temperature spray dryer, the laboratory spray freeze dryer and others.
Do Pilotech’s Products come with an English Interface?
Yes, it does, although not all. You could choose which but it also provides you with the preferred language of your choice.
Can I order a Pilotech product from China?
Yes, you can. Pilotech ships to all countries worldwide.
Do I get a warranty if I purchase a Pilotech product?
Yes, Pilotech offers all their esteemed customers a one-year warranty on all purchased products. The refund and return policy is also quite customer-friendly.
It has been an incredible journey, we must say, taking you through the world of LAB GRANULATORs by Pilotech. We hope this article has given an in-depth insight into spray granulation, the types, and techniques involved in granulation. You have the requisite knowledge on this incredible Pilotech product. If you are interested in going into a business that requires the use of a LAB GRANULATOR, this article is for you. Don’t forget to contact Pilotech for quality LAB GRANULATORs to kick start your business.
Laboratory Granulator: The Ultimate FAQ Guide
In this guide, you will find all information about laboratory granulators.
Whether you want to learn about the classification criteria, working principle, or how to optimize the entire process – you will learn everything here.
Keep reading to learn more.
- What is Laboratory Granulator?
- Which are Types of Laboratory Granulator?
- What are the Benefits of Laboratory Granulator?
- Which are the Qualities of the Best Laboratory Granulator?
- Which are the Main Parts of Laboratory Granulator?
- How Does Laboratory Granulator Work?
- Do Laboratory Granulators have Special Requirement on Granulating Fluid?
- What are the Factors to Consider When Choosing Laboratory Granulator?
- Which Factors Affect Granulation Process in Wet Laboratory Granulator?
- What is the Role of Binder in Laboratory Granulator?
- What is an Oscillating Granulator?
- What is the Difference Between Wet Granulator and Dry Granulator?
- What is the Difference Between Pellets, Granules, and Powder in Laboratory Granulator?
- What is the Purpose of User Requirement Specification (URS) of Laboratory Granulator?
- What are the Advantages of Laboratory Dry Granulator?
- What are the Advantages of Laboratory Wet Granulator over Dry Granulator?
- Which are the Material Properties that Influence the Design of Laboratory Granulator?
- Why is Testing During Laboratory Granulator Design Important?
- What is Single Pot Technology in Laboratory Granulator?
- What are the Advantages of Pneumatic Dry Granulation?
- How is Agglomeration Important in Laboratory Granulator?
- What is the SOP for Laboratory Granulator?
- Which Industries Use Laboratory Granulator?
- Which are the Quality Certifications for Laboratory Granulator?
What is Laboratory Granulator?
Laboratory granulator refers to equipment having an oscillator rotor used for the production of granules.
It produces the granules in different sizes based on the type of sieve mesh you use.
There are several types of laboratory granulators enabling either dry or wet granulation.
All laboratory granulation machines facilitate easy and effective processing.
Which are Types of Laboratory Granulator?
Here are the main types of laboratory granulators available:
· Laboratory Fluidized Bed Granulator
In this laboratory granulator type, the system subjects the solid particles to a designated pressure amount, making them act like a fluid.
Typically, there are three vital stages in the fluidized bed granulation process including fluidizing the granulation bed, adding granulating fluid, and drying granules.
· Laboratory Wet Granulator
As the name suggests, this machine facilitates wet granulation of particles.
A laboratory wet granulator uses granulating fluid to enlarge the particles, usually boosted by an impeller.
· Laboratory High Shear Granulator
This refers to laboratory equipment used in mixing and granulating particles.
The machine derives its name from the extremely high speed it applies during the mixing and granulation process.
Laboratory high shear granulator guarantees efficient granulation even if auxiliary and main materials feature significant differences in specific density.
Moreover, it produces firm and homogenous granule products.
· Laboratory Dry Granulator
The most common type of laboratory dry granulator is a roller compactor.
This dry granulation machine produces extremely stable granules without the addition of any granulating fluid and ensures dust-free operation.
It performs powder dry compaction between 2 rollers at high pressure to form granules with increased bulk density.
Most roller compactors allow three functions in a single laboratory granulation machine, including compression, milling, and granulation.
The hydraulic system pressure is variable to suit a wide variety of materials.
Moreover, operating a laboratory dry granulator is simpler compared to a wet granulation machine.
What are the Benefits of Laboratory Granulator?
The main advantages of laboratory granulation equipment include:
- Allows dust-free process of granulation
- Enhances flowability of a material
- Enhances material dispersion
- Increase porosity to optimize the rate of dissolution
- Helps in changing the bulk density of granules
- Changes shape, size, and surface smoothness of material for coatings
Which are the Qualities of the Best Laboratory Granulator?
Here are the essential qualities of an ideal laboratory granulation machine:
- Must have the potential to enhance repeatability in the performance of the product
- Should minimize instability in the operation performance
- Must exhibit the capability to decrease changes in the post-approval process.
- Must possess the potential to reduce time and cost
- Needs to generate spherical granules having appropriate structural stability, specific intra-granular porosity and controlled size distribution.
Moreover, the produced granules should feature specific bulk density excellent physical strength, compatibility and flowability.
Which are the Main Parts of Laboratory Granulator?
Because of the different types of laboratory granulator, here are the key components of high shear granulation machine:
Parts of the granulator machine
· Granulation Drum/Container
Also known as a mixing drum, it refers to a stainless steel container fitted with blending tools and accessories.
The granulation drum accessories comprise of impellers, mixing blades, choppers and spraying nozzle.
It is instrumental in separating the granulator’s mixing chamber from the exterior environment.
The laboratory granulator impeller aids in material mixing and spreading of granulation fluid at varying rotational speeds.
Its rotation can either be horizontal or vertical based on the granulation machine orientation.
· Granulator Chopper
Laboratory granulator chopper refers to an auxiliary impeller that spins at a comparatively higher speed spanning from 1000 to 3000 rotation/minute.
It has U-shaped blades that help in breaking down wet lumps leading to the creation of granules.
· Motor Drive Mechanism
This is the system that drives the chopper and impeller of the laboratory granulator.
Moreover, the motor drive system is instrumental in regulating the granulation process.
The majority of laboratory granulation equipment comes with an adjustable frequency drive mechanism.
This enables you to vary the speed of rotation for optimal granulation.
· Spraying Nozzle
Spray nozzles are important in the atomization of feed material and supply appropriate droplets of binder solution during granulation.
In addition, it uniformly spreads the binder solution on the raw material.
Here are the main factors that you should consider when selecting the best spray nozzle:
i. Granulation solution pump that may either be peristaltic or mechanical based on the products you are granulating.
ii. Pressure pot of granulating fluid that makes sure there are high pressure and quick delivery of granulating fluid.
· Safety Mechanism
A safety interlock system prevents you from accessing the drive system of the laboratory granulator when it is in operation.
Furthermore, it prevents the operation of the equipment if the granulation drum is open.
· Granule Discharge System
This is the part of the laboratory granulation machine that permits and guides the end products via the discharge port for supplementary processing.
There are different versions of granule discharge systems based on the design and type of laboratory granulator.
· Control Panel
The complexity of most control systems normally relies on the design, configuration, and control software of the laboratory granulation equipment.
The majority of modern laboratory granulators feature HMI control systems or touchscreen PLC panels.
The primary roles of the control panel include the following:
i. Adjusting the various granulation process parameters
ii. Showing system parameters like temperature and speed of impeller and chopper.
This is the main structure that holds the other components of the laboratory granulator such as the impeller and spray nozzle.
The machine frame needs to be sturdy enough to sustain the weight and granulation process vibration.
· Sealing System
These refer to Teflon seals used to prevent leakages during the operation of the laboratory granulator.
Most machines incorporate the sealing system on the chopper and impeller shafts.
How Does Laboratory Granulator Work?
Let’s briefly look at the principle of operation of the different types of laboratory granulator:
1. Laboratory Fluidized Bed Granulator
The fluid bed granulation process is similar regardless of the laboratory granulator layout.
The reason for this is the similar position of the fluid bed spray procedure in all versions of this type of granulation machine.
Fluidized bed granulation machine generally entails three essential stages:
· Fluidize the Wet Granulation Bed
The first step is heating air to desired temperature and filtering before pumping into granulation drum or bed of unmixed materials.
You may incorporate a pump or fan based on fluid bed technology.
For that matter, a fluidized bed granulator may either draw or blow air into a powder container.
Adjusting the flow of air up to a specific level makes the particles act like fluid, leading to a fluidized bed.
Fluidization is an effective particle mixing process and is ideal for both thermo-labile and non-thermo-labile materials.
· Addition of Granulating Fluid
In most laboratory fluidized bed granulators, the location of the spray nozzle is at the top.
Nonetheless, for machines involving both granulation and coating, the location of the spray nozzle is on either side of the equipment.
With a fully fluidized bed, the system pumps granulating fluid from the repository to the spray nozzle.
As powder particles collide with one another in the granulation fluid presence, they stick to each other creating granules.
Ensure to spray the granulating fluid continually till the laboratory granulator produces the desired granules size.
However, the system will blow away some of the particles, thus the need for fitting an exhaust filter.
The exhaust filter is instrumental in trapping the blown particles.
To let out all caught particles of powder into bed, you should agitate the filter periodically.
· Drying Granules
This is a vital stage in the laboratory fluid bed granulation machine.
After forming the size of the required granules, you turn the spraying nozzle off.
Nevertheless, the heated fluidizing air will keep flowing across the bed, hence drying all generated granules.
2. Laboratory Dry Granulator
Roller compactor for dry granulation
The most common type of dry granulator is a roller compactor.
Also referred to as chilsonator, this type of dry granulating machine generates a sheet of granules by compressing powder between 2 rolls.
It comprises 2 driver rollers moving in opposing directions from the inner side to the outer side.
Made of stainless steel, rolls have teeth to generate a strong grinding effect by thrusting material on a sequence of disintegrating combs.
The three main parts of a dry granulation machine include:
- Feeding system which is the unit helping in powder transfer to the compaction section between the rollers.
- Compaction unit where powder compaction to ribbons takes place. The compaction happens between 2 counter-rotating rollers through the application of force.
Size-reduction unit for ribbons milling to the required particle size.
The powder material passes via the roller compactor’s 2 counter-revolving rolls under extremely high pressure.
Counter revolving rolls.
As volume reduces across the maximum pressure region, the dry granulator converts material to flakes or rigid dense sheet of ingredients.
The machine reduces the size of these dense sheets or flakes of ingredients to attain the wanted grain size.
Roll compaction granulator ensures there is negligible production of fine through the granulation process.
Fines generated during the process are extremely low (maximum 25 percent).
Actually, it is possible to decrease to 15 percent through careful process adjustment.
3. Laboratory Wet Granulator
Laboratory wet granulator
There exist various types of laboratory wet granulation machines having different working principles.
But, wet granulation process typically involves adding binder material and granulating solution to agitated powder bed to produce granules.
Popular types of laboratory wet granulators are fluidized bed granulator and high shear granulator.
Therefore, let’s look at the working principle of laboratory high shear granulator.
· Laboratory High Shear Granulator
Laboratory high shear mixer granulator
Also known as laboratory mixer granulator, the main components of a high-shear granulation machine include:
- Conical/cylindrical mixing bowl
- Three-bladed impeller
- Secondary chopper
- Motor to steer the blades
- Discharge pot
The system either circulates cool or hot steam or liquid across the jacket.
This helps in cooling or heating the bowl content depending on the aim.
Here are the 5 main stages involved in the wet granulation process utilizing laboratory high-shear granulator:
- Powder mixing
- Addition of binder or granulating liquid
- Powder wetting and nucleation
- Granules growth and powder densification
- Attrition and breakage of granules
The rotation speed of the impeller used in dry powder mixing and granulating fluid spreading ranges from 100 to 500 rpm.
Likewise, the chopper helps in breaking down the wet lump leading to the development of granules.
The speed of rotation of the chopper ranges from 1000 to 3000 rpm.
Introduction of granulating solution into the powder under high power because of spinning high-shear forces aids in densification/agglomeration of powder.
Do Laboratory Granulators have Special Requirement on Granulating Fluid?
Yes, there exist specific conditions for granulation fluid used in laboratory wet granulator.
The fluid should incorporate a non-toxic, volatile solvent and which is easy to remove by drying.
The common solvents of granulating fluid consist of methylene chloride, water, ethanol, and isopropanol.
You may either utilize the granulation fluid independently or in solution constituting gelatinized binders, binders, or suspensions.
In addition to the above conditions, the granulation fluid ought to make sure that particles adhere together after drying of granules.
What are the Factors to Consider When Choosing Laboratory Granulator?
Checking the technical specifications of a laboratory granulation machine is an important step when shopping for a granulator.
This entails checking the technical data or machine manual.
Here are some of the key factors to consider to select the best laboratory granulator for your applications:
· Granulator Dimensions
This constitutes the size of the laboratory granulator and measurement of other components, including lengths and diameter.
In addition, you should as well consider the net weight of granulator equipment.
· Operating Speed
Here, you factor in the rotation speed of the equipment or rotor speed.
This is vital in letting you determine the number of granules you can produce within a particular time.
· Granulator Capacity
The capacity of laboratory granulation equipment will determine raw material amount you can feed in the process.
Moreover, it dictates quantity of granules produced within a given period of time.
· Granulator Model
There exist several models of laboratory granulator that you can select from.
Nevertheless, it is advisable to opt for a renowned brand.
· Power Requirements
Different designs and types of laboratory granulators have differing energy requirements.
Therefore, it is essential to choose equipment fit perfectly in your country’s power grid.
· Level of Automation
Laboratory granulation machines come with different modes of operation, either automatically or manually operated.
It is advisable to choose automatic granulator having PLC control systems although it may be more expensive.
· Quality of Laboratory Granulator
You need to ensure that the machine of choice complies with relevant quality standards related to it to avoid buying counterfeits.
Which Factors Affect Granulation Process in Wet Laboratory Granulator?
The following factors may influence the granulation process during operation of the laboratory granulating machine:
· Material Characteristics
Granulating characteristics of raw materials rely on constituents of the different ingredients found in the feed material.
Lubricity and adhesion are the most critical granulating properties of raw material.
· Type of Excipients
The purpose of excipients in granulation operation is very essential.
The type of adhesive you use is very key in the granulation process of the laboratory granulator.
If not selected correctly, it will not just impact on the quality of the particle, but also the particles.
You should choose the adhesive depending on the solubility and wettability of the powder.
For instance, use a highly viscous adhesive in comparatively large amount when powder utilized for granulation is or has:
- Loose texture
- Low water solubility
- Poor viscosity
Moreover, there is need for a moistening agent.
You equally should choose the wetting agent based on the powder properties.
· Mixing Speed
After adding adhesive to the raw material, you stir the mixture at moderate and high speed.
After granulation, you may stir it at low speed.
Based on the circumstance, it is acceptable to use similar speed to convey it through.
When you increase mixing speed, there will be uniform particle size distribution, though average diameter of particle inclines to increase.
On the other side, in case the speed is extremely high, material will adhere on the wall of the mixing container.
· Feed Flow
Adjust feed flow rate depending on the granulated raw materials properties and specifications towards end products.
Moreover, you should maintain its consistency to facilitate normal laboratory granulator operation and quality and yield of the granulated product.
What is the Role of Binder in Laboratory Granulator?
The binder is also a very critical ingredient when operating a laboratory granulator.
Binder plays a role in the success of the granulation process in 3 main ways:
i. Encourage Particle Growth (Accretion Or Coalescence)
The binding agent enables particles to get tacky and gather more fines.
If you do not use a binder, particles would just fall in the laboratory granulation machine, without the growth of particles.
ii. Ensuring Suitable Green Strength
Green strength refers to the pellets or granules’ strength in their wet state before drying.
Attaining and sustaining a sufficient green strength enables the products to remain whole throughout the granulation process.
There are usually several drops and transfer points between the laboratory granulator and the finished product.
Therefore, it is essential to maintaining particle integrity during the process to make granules do not disintegrate during processing.
iii. Achieving Required Crush Strength
The binder is equally instrumental in determining the crush strength of the finished product, enabling it to endure handling, storage, shipping, and application.
Essentially, dry crush strength makes sure that the product reaches its destination as expected.
These guarantees use of the product precisely as produced, without prematurely disintegrating into fines.
There are various types of binders used in laboratory wet granulators, with each featuring unique characteristics in composition and performance.
Based on the desired properties of the end product and material feedstock, certain binding agents will be more effective than others.
What is an Oscillating Granulator?
This is a type of laboratory granulator utilized for gentle coalescing, size reduction, sorting, and screening dry sensitive granules and powders.
Oscillating Granulator features one rotor having 5 edges, which swings on the horizontal centerline at approximately 180/minute.
It has a half-circular sieve installed at the rotor base.
Feeding of products happens from top via in-feed hopper and raw materials drop on blades of the rotor.
A combination of oscillating bars ordered in a cylindrical manner above a screen of appropriate mesh break down the particles.
Because of the rotor sharp edges, particles downsizing happens and via sieve, the system pushes materials outward through base opening.
What is the Difference Between Wet Granulator and Dry Granulator?
Here are the main ways how laboratory wet granulator differ from laboratory dry granulator:
· Moisture Presence
Laboratory dry granulator entails the formation of granules without the use of any liquid solution.
Conversely, all types of laboratory granulators involve the use of granulating fluid.
The granulation process using dry granulators entails direct compaction of raw material to form granules.
On the other hand, wet granulation entails blending granulating fluid and feedstock material to form wet granules.
Dry granulation machine needs finely ground materials.
Conversely, laboratory wet granulators require granulating fluid, powder particles, and excipients (binders/adhesive).
Laboratory dry granulators are best for granulating highly heat- and moisture-sensitive materials.
On the contrary, wet granulation equipment is ideal for preventing the destruction of active ingredients within the raw material.
What is the Difference Between Pellets, Granules, and Powder in Laboratory Granulator?
The primary difference between pellets granules and powder is the size of the particle.
Powder refers to dry, fine-grained particles that you may produce by crushing, grinding or disintegration of a solid.
It normally features the tinniest particles compared to pellets and granules.
Granule refers to a minute compact part that develops due to the fusion of different particles of powder.
Granule particles are bigger than powder particles though smaller than pellet particles.
Pellet describes a tiny or round material formed by compressing various materials.
It features the biggest sizes of particles among the 3 types.
What is the Purpose of User Requirement Specification (URS) of Laboratory Granulator?
User Requirement Specification refers to a document produced by a laboratory granulator buyer to detail precisely the desired mechanical properties.
After preparing the URS, you send it to the manufacturer of the laboratory granulation machine to follow.
You develop the URS early during the process of validation, normally before the manufacturer creates the granulation system.
Requirements outlined in the URS are usually tested in the Performance Qualification or User Acceptance Testing.
It should not be technical documentation.
Readers having just general knowledge on the equipment need to comprehend the requirements highlighted in URS.
Generally, URS serves as a planning document, developed when you are planning on purchasing laboratory granulator and is attempting to establish specific needs.
However, in some cases you can combine the URS with the functional requirements document.
This happens if the manufacturer has already created the equipment, you have already bought it, for least complex systems.
What are the Advantages of Laboratory Dry Granulator?
Here are the key benefits of using dry granulation machines:
- Require reduced floor space
- Easy to clean machine after use
- Roller compactor is ideal for both batch production and hard continuous process
- Eliminates need to add heat and moisture
- Ensures uniform mechanical strength of finished product.
- Low cost of operation and exceptionally efficient operation
- Eliminates the requirement for binding agent
What are the Advantages of Laboratory Wet Granulator over Dry Granulator?
Different from dry granulating equipment, laboratory wet granulation machines develop more spherical granules.
These types of granules provide a number of benefits that makes this type of laboratory the most preferred in the market.
Here are the main benefits of laboratory wet granulators:
- Reduced dust and attrition
- Enhanced product flowability
- Superior handling and use qualities
- Greater control level over particle properties
- Easy incorporation of beneficial additives
- Greater porosity
Which are the Material Properties that Influence the Design of Laboratory Granulator?
Let’s look at the most essential material properties that you must consider when designing a laboratory granulator:
· Bulk Density
This is an important factor when sizing the granulation drum since it dictates volumetric throughput.
You must consider both required bulk density and raw material feedstock during sizing because the granulator should be capable of accommodating both.
The material volume at required capacity (volumetric throughput) describes load put on granulation drum, thus the amount of energy needed.
Therefore, the selection and design of all granulation drum components rely on this working load.
· Moisture Content
Feedstock moisture content is equally a crucial factor in the sizing and designing of laboratory granulator.
In wet granulator, optimal granulation happens within a definite moisture range that is distinct to every material.
Materials falling outside the designated moisture range have higher chance of not granulating completely, or will produce poor-quality granules.
Incoming material moisture content will dictate amount of liquid binder required, and usually, point(s) within the drum to distribute the binder.
Feedstock that is above granulation threshold will need a drying procedure to reduce moisture content before processing in laboratory granulator.
Material moisture content equally influences the tumbling of the bed.
This might require the application of tumbling flights that helping in turning the bed over and enhance blending and granulation.
Moreover, you need to also consider discharged product moisture, which is commonly referred to as wet or green pellets.
Attaining required outlet moisture assists in keeping granules whole all through granulation process and transfer points before ultimate drying.
The property is known as green strength.
The inlet and exit moisture difference also dictates the binder amount required to attain the desired exit moisture.
· Particle Size Distribution
It is important to factor in the size distribution of both incoming and required particles into laboratory granulator design:
i. Particle Size Distribution of Desired Granules
You control the desired finished product size through residence time, which the drum sizing largely controls.
You will need more residence time in case you need larger granules, which means a larger drum.
ii. Particle Size Distribution of Incoming Material
The particle size distribution of raw material is vital in producing a good, robust product.
Although it doesn’t definitely affect the design of the drum itself, it will influence the system design in general.
Incoming particles should be smaller in comparison to the desired finished product size.
Additionally, they need to have good particles cross-section within the designated range optimal for granulation.
Good particle size cross-section encourages efficient agglomeration.
It does this by permitting finer particles to occupy gaps between bigger ones and develop a robust green product.
Particles above the required size range will need some kind of size reduction acting as a preconditioning procedure prior to laboratory granulator.
· Chemical Composition
The chemical composition of the feed material is as well a critical factor in granulating drum design.
Based on the chemical constitution of a specific material, it might present sticking, abrasion, corrosion, or other problems.
You can address these problems through a cautious selection of construction materials, together with the incorporation of liners or supplementary internals.
The temperature of incoming material is not normally a consideration when designing a laboratory granulator.
However, you need to consider if it is likely to affect the material’s physical or chemical nature.
You will need more liquid binder or water when the incoming material temperature is beyond water’s boiling point.
Why is Testing During Laboratory Granulator Design Important?
The simple and dependable granulation drum operation can be deceptive, giving the perception that it involves little engineering.
However, the stable functioning, minimal supervision, and regular production of the desired product are in fact due to a laboratory granulator meticulously designed.
Contrary to the smooth functioning of a carefully designed granulation machine, a poorly-engineered is prevalent with problems.
The issues include the inability to create the desired product, lost production, a high rate of operation upsets, and endless troubleshooting.
Moreover, not all processes of granulation are physically and/or economically viable.
Therefore, a detailed testing scheme should often be the initial phase in the design of a laboratory granulation drum.
This should apply whether the equipment will be for an existing application or new one.
With several interdependent parameters, testing plays a number of roles.
It assists engineers to realize the most optimal design of granulation drum for the intended application.
The unknown behind well-engineered laboratory granulation equipment is knowing that every material reacts uniquely to granulation.
This variance requires that you thoroughly analyze the proposed feedstock for a particular process.
Analyzing the feedstock helps you establish if it is or not compatible with the planned granulation process.
It also helps in determining how you can design the granulating machine to operate perfectly with the distinctive feedstock material properties.
Testing will aid in identifying the variables needed for developing the required granular product out of the feedstock material.
Further, it helps in establishing whether or not you will need a preconditioning stage to bring raw material to specific parameters range.
Materials successfully granulated on a bench/batch scale usually present unforeseeable problems on scale-up.
Therefore, pilot-scale testing is instrumental in identifying these issues early, minimizing chances for surprises in future.
Furthermore, testing enables engineers to modify the design appropriately before constructing the laboratory granulator.
Likewise, testing creates a beneficial conversance with material that may quicken future troubleshooting.
For example, it is possible to identify an issue due to an anomaly in the feedstock, where the possibility of other issues may exist.
This is due to the fact that testing determines the distinct scope in which raw material must be for any specific parameter.
What is Single Pot Technology in Laboratory Granulator?
This refers to a laboratory granulator capable of drying granules in similar machine without discharging them.
The granulation process happens in an ordinary high shear processor.
Nevertheless, you need to be keen to prevent the development of lumps since you cannot break them down before drying.
There exist several choices for drying granules in single pots.
The primary drying principle depends on vacuum application in the granulation bowl, which lowers the vaporization temperature of the granulating fluid.
The traditional source of heat comes from walls of the heated dryer.
Heat transfer depends on volume of material treated and dryer walls surface area.
Thus, this direct method of heating is most efficient for low binder fluid quantities, or pilot-scale, organic solvents.
Injecting stripping gas in the pot enables you to achieve extremely low ultimate moisture content (only necessary in specific granulation applications).
You introduce a small gas quantity at the equipment base, which flows across product bed, enhancing vapor removal efficiency.
Nonetheless, since the heated wall is the sole drying energy source, it not possible to achieve linear scale-up.
A heat-sensitive material exacerbates this problem since this restricts wall temperature.
The problem is more serious when you use water as granulation fluid due to its comparatively greater boiling temperature in a vacuum.
Additionally, water features a high heat of vaporization in comparison to organic solvents.
Moreover, the surface/volume ratio decline with increasing volume if you use a single-pot processor for mass production.
Fortunately, you can employ microwave energy to get control of these limitations.
It offers an extra energy source and has extra benefits with organic solvents.
Most laboratory granulators require that the system treats only flawless organic vapors on the outlet side.
But using microwave energy allows treatment of a blend of solvent and sizeable process gas volumes.
Fluidized bed granulator
What are the Advantages of Pneumatic Dry Granulation?
Pneumatic dry granulation is a modern and patent-pending innovation.
The new granulation procedure relies on the application of roller compaction featuring low compaction force coupled with a proprietary method of air classification.
It facilitates the development of granules having an exceptional combination of compressibility and flowability.
Pneumatic dry granulation process can attain:
- High drug loading in the pharmaceutical application, even with problematic combinations and APIs.
- Exceptional stability
- Taste masking
Here are the advantages of pneumatic dry granulator:
- Quicker granulation speed in comparison to laboratory wet granulation machine.
- Reduced manufacturing cost compared to wet granulation
- The closed system provides safety benefits because of low levels of dust and the possibility of sterile manufacturing or handling of harmful materials
- Produces very stable finished products, which may enhance their shelf life
- Negligible or no material waste
- Straightforward Scale-up
- Produced granules exhibit rapid disintegration attributes, giving a capability for quick release dosage forms
- Allows customization of release time to requirements
How is Agglomeration Important in Laboratory Granulator?
The capability to control the size of voluminous solids is an important element to the success of several operations and products.
It enables more effective production, more foreseeable outcomes, and eventually a better-finished product.
Agglomeration provides the unique potential to refine particle size to produce perfect material properties for application as a feedstock or final product.
It refers to a procedure of enlarging particle size by amassing material fines to a bigger, cohesive particle.
Laboratory granulators used in broad range of sectors employ agglomeration.
The particle size enlargement process has the ability to transform hard to handle or dusty materials to more acceptable form.
Here is a summary of the benefits of agglomeration in laboratory granulation machines:
1) Product Benefits:
- Dust-free handling/Dust suppression
- Prevention of Segregation
- Enhanced appearance
- Improved properties and commonly, performance
2) Raw Material Benefits
- Simplified transportation
- Improved melting capabilities, porosity, and density
- Dust loss mitigation
3) Process Benefits
- Fines and dust elimination
- Enhanced process flow efficiency
- Raised process efficiency
4) Economic Benefits
- Waste material transformation into the marketable end product
- Reduced costs of transportation
- Minimized costs of handling
5) Environmental Benefits:
- The decreased necessity for landfill
- A chance for waste-to-fuel applications
- Enhanced cost-efficiency of waste disposal
What is the SOP for Laboratory Granulator?
Here are the Standard Operating Procedure for laboratory granulation machine:
1. Pre-start Up
- Make sure that the production section is clean.
- Confirm that you have selected the right materials for the granulation process.
- Take off the “cleaned” tag from the equipment after confirming the information presented (particularly previously utilized materials).
- Put the equipment tag on the laboratory granulator.
2. Start-Up and Running
- Wear protective latex gloves during materials loading and unloading
- Open the granulator lid and charge material into the bowl according to the sequence stipulated in Batch Manufacturing Record (BMR).
- Shut the lid and fasten the 2 locking clamps.
- Set dry mixing speed as designated in BMR. Switch the power on and begin the process of dry mixing. Run the machine for specific mixing duration.
- Slow down the granulator impeller as stipulated in BMR to speed needed for addition of binder. Via solution inlet port, add binder solution to the mixed material.
- Set the speed of impeller according to BMR and for process of wet mixing, and let it run for needed duration.
- Increase speed and configure speed of chopper to that necessary for granulation. Confirm often to make sure that there is complete granulation.
- Open discharge port and let the wet materials flow into fluidized bed dry bowl found below the discharge gate.
3. Shut Down
- Stop the impeller and chopper, and open-top lid of the laboratory granulator. Eliminate any residual blend by brushing it from the walls of bowl.
- Ensure that you have eliminated all remaining materials.
- Turn off main power supply
B. Cleaning Procedures
1. Cleaning through Batch Changeover, though with Similar Product
- Make sure that the laboratory granulator and space around it is clean.
- Detach the “cleaned” tag from the equipment.
- Put the machine “in use” tag on the equipment.
2. Cleaning In Product Changeover
- Ensure that the laboratory granulation machine and space around it is clean and lacks materials and waste from preceding products.
- Check and analyze “rinse water analysis report” then stick to BMR.
- Take off the “cleaned” tag from the granulator.
- Inspect the room temperature and relative humidity, ensuring to record it in BMR log.
- In case the temperature falls outside the designated limit, notify maintenance team. Do not continue you change the relative humidity and temperature to required standard.
3. Cleaning During Shutdown, or Product Changeover (Material of Ascending Potency)
- Use lint free cloth or vacuum cleaner to eliminate loosely adhered powder.
- Disassemble the parts of laboratory granulator and detach them in order:
- Dome of Agitator
- Blade of Chopper
- Stainless steel bolt
- Utilize vacuum cleaner or lint-free cloth to cleanse the disassembled parts.
- Clean the granulation equipment and disassemble the components using lint-free cloth.
- Clean processing section according to the SOP.
- Assemble the components after cleaning.
- Attach the “cleaned” tag to the laboratory granulation machine.
- Record the cleaning specifics in the BMR log.
4. Cleaning During Product Changeover (Similar Material Of Descending Potency) – Preventative Contact Parts Maintenance
- Clean the granulator mixer and surface of an assembly utilizing moist duster succeeded by dry clean duster.
- Fill the granulating bowl with water to a third of its volume, shut the lid, and operate the chopper and mixer for five minutes.
- Collect the cleaning water, for instance, by putting a stainless steel drum below the discharge gate.
- Open top lid, take out the blade and dome of the agitator by unfastening the locking nuts.
- Disassemble the blade of the chopper by unfastening the belt, and eventually detach the washer and blade.
- Move the blade of the chopper and agitator to the cleaning section, and wash both components under a water jet. Scrub them utilizing a clean nylon brush.
- Brush sticky powder using a nylon brush and clean the bowl vigorously to eliminate any observable material sign.
- Inspect below the chopper and dome crevices, chopper blade, locking nuts and discharge ports to ensure that the laboratory granulator is evidently clean.
- Use purified water to rinse the granulation equipment and parts. Send the rinse water sample to QA to verify that is does not contain substances from the preceding batch.
- Put “cleaned” tag on the laboratory granulation machine.
- Document the details of cleaning in the BMR log.
Which Industries Use Laboratory Granulator?
Most applications of laboratory granulators are in the following industries:
- Fertilizer manufacturing Industries
- Chemical Processing Industries
- Pharmaceutical Industries
- Food and Beverage Industries
Which are the Quality Certifications for Laboratory Granulator?
Here are the important quality certifications that the best laboratory granulation machine should comply with:
- ASTM E2500 certification
- ISO Certification
- cGMP compliance
- CE compliance
At Pilotech, we offer a range of laboratory material processing equipment including a spray dryer machine, lab freeze dryer, and extruder spherionizer, amongst others.
Contact us today for all your laboratory granulator needs.