Pilotech Spray Granulator Leading Manufacturer

Spray Granulator Machine: The Complete Buying Guide

Spray granulators are widely used in various industries such as fertilizers, pharmaceuticals, ceramics, foods (especially instant foods), industrial chemicals, materials, resin processing, etc.

Briefly speaking, our spray granulator works by spraying the binder solution onto the fluidized powder material in the chamber. The powder first in contact with the droplets would be wetted and form a core for the accumulation of more droplets and powder particles. Newly added droplets form fluid bridges between smaller particles, which is dried to form solid bridges, or the materials accumulate layer by layer to form larger granules.

Our spray granulator can also work this way: The major material is in liquid and atomized by the spray nozzle into the chamber; the fluidized bed charge act as the core to allow the droplets accumulate onto them to form desired large granules.

Pilotech spray granulator is designed for small-scale experiments and pilot-scale trials, with capacities of 5kg, 3kg, 1kg, 500g, and 300g. The granulators can process a minimum of 100g material and a maximum of 5kg material each batch and can produce a maximum granule size of 5mm.

Our spray granulator can also be used for coating and drying. When used for coating, the coating material is spayed from the bottom and can make an even and firm coating for granular materials or pills.

If required, we can also equip the spray granulator with multi-stage HEPA filtration, the data can be cured in full compliance with GMP regulations.

For the 3kg and 5kg spray granulators, two top spray nozzles are equipped and can be switched online to meet the needs for larger granules.

We have added spray drying function to the 1kg spray granulator, so you won’t have to buy a separate laboratory spray dryer.

If you want to get more information, contact us now, please.

1. Introduction – What is Granulation?
2. What Are Types of Granulation?

2.1 Wet Granulation

2.2 Dry Granulation

3. Different Types of Granulators Along With Their Applications
   3.1 – Reverse wet granulator

3.2 – Foam granulator

3.3 – Rapid Mixer Granulator
3.4 – Freeze granulator

3.5 – Spray Granulator

3.6 – High-shear Granulator

4. Production History of Pilotech Fluidized Bed Spray Granulators
5. Working Principle of Pilotech Fluidized Bed Spray Granulator
6. The Main Components of Pilotech Fluidized Bed Spray Granulator
7. The Main Features of Pilotech Fluidized Bed Spray Granulator
8. Application Range of Pilotech Fluidized Bed Spray Granulator
9. Users of Pilotech Fluidized Bed Spray Granulator
10. What are Different Types of Laboratory Fluidized Bed Spray Granulators of Shanghai Pilotech?

10.1 YC-1000 Laboratory Granulator (Fluid Bed)

10.2 Lab Fluidized Bed Spray Granulation YC-03

10.3 Lab Fluidized Bed Spray Granulation YC-310

11. Factory Inspection of Pilotech Fluidized Bed Spray Granulator
12. Pilotech Fluidized Bed Spray Granulator – General FAQs

12.1 Why Granulate Powder in Material Processing?

12.2 What Are the Parameters of Fluid Bed Granulation Process That May Affect the Quality of Granules?

12.3 What Are the Fluid Bed Granulation Process Variables?

12.4 What Are the Formulation Variables Available in Fluid Bed Granulation?

12.5 What Are the Variables of Fluid Bed Equipment That Affect the Effectiveness of Material Granulation?

13. After-Sales Service at Shanghai Pilotech Instrument & Equipment Co., Ltd.
14. Final Thoughts!

Shanghai Pilotech Fluidized Bed Spray Granulators

One of the popular material processing techniques in many industries is the fluid bed granulation. Various industries are using it for transforming dusty powder into granules.

But before we explore the process of fluid bed granulation, let us review the general concept of the granulation process.

1. Introduction – What Is Granulation?

Granulation is the best way of making granules. It will process small substances into bigger particles. Here the tiny materials could be anything such as dust, spray-dried powder, etc. You can complete this through various means. For instance, you can use compaction to form pellets or tablets from solid materials.

It is the method that many material processing industries are using, such as pharmaceutical, foodstuff, and chemical industries. Moreover, it is a standard process in making thick dosage drugs where it changes formulations with improved compaction and flows characteristics.

The process will ensure the resulting product has a consistent texture and uniform content. So, while you are doing the process of granulation, the particles stick to each other. It results in a larger, well-built size of granules.

2. What Are Different Types of Granulation?

Depending on the application, a couple of granulation types are widely used. So, you can choose the suitable type according to your requirements.

There are two types of granulation techniques – Dry and Wet Granulation.

2.1 – Dry Granulation

Firstly, in this method, you can create granules without the need for any solution. It is suitable for moisture-sensitive materials, which compacts and densify the powder to form granules.

You can perform this method in two different ways. In the first approach, you can create a large tablet in a heavy-duty tabletting press. Or else, you can squeeze the powder between two separate rollers that are counter-rotating. It will help you make a constant sheet.

There are machines that you can use in this process, and one of them is the roller compactor. The method is cost-effective and straightforward but repeated compressing cycles may provide you with tablets of poor quality.

2.2 – Wet Granulation

In the Wet Granulation process, all you need is a binder or liquid that creates aggregation of particles. This process may appear technical, especially during the procedure of making a liquefied bed of material.

The good news is, you will learn about all aspects of fluidization and fluid bed granulation in the succeeding section of this article. It will be the main focus.

So, before that, you need to remember the following essential aspects of the wet granulation method:

Wet granulation requires you to use liquid

• The liquid used in wet granulation is a light solvent that is removable easily by drying
• It should be non-toxic

For the wet-granulation procedure, you have to choose the liquid based on the materials that you want to process. Fluids may include any aqueous solution, ethanol, isopropanol, or even water.

3. Different Types of Granulators Along With Their Applications

There are different types of equipment for granulation available. Besides, industries have lots of choices as to the nature of granulator that they need based on their requirements.

Below are the commonly used and advanced types of granulators.

3.1 – Reversed Wet Granulator

To get started, you must plunge the dry powder into the binder liquid. After that, there comes a role of controlled breakage that will break or split them into granules.

One thing about granules is sure that they can have the best ever flow. The granules are more delicate in texture with its tiny spherical shape. It will grind the sparse water-soluble particles by this technique.

3.2 – Foam Granulator

You can get the foam with this Foam generator, and when using this equipment, you can use the liquid binder. The reason why you should use it because it will help decrease the issues that may come up with a granulating machine. These issues may include several factors such as inconsistency or uneven distribution of the binder.

The drug is softer, and the spread soak ratio is higher. It means the process helps to coat the powders warmly and makes the binder circulation uniform.

One benefit that manufacturers get here is the decreased time of processing. Also, the machine removes the clogging of spray nozzles, and the distribution of granules forms the low dose tablets easily.

3.3 – Rapid Mixer Granulator

Most of the pharmaceutical manufacturing companies are using Rapid Mixer Granulator. This equipment can mix ingredients, and create granules before compression, which is why it is also known as the shear mixer.

The formation of granules happens by the motion of materials like rising, spinning, and tumbling. With this granulator, it is easier to mix all the ingredients with the help of impellers and choppers set at high speed. However, you can also set it at a slower pace depending on the mixing requirement of the final product. It is possible to design granular particles with the proper operation.

3.4 – Freeze Granulator

In Freeze Granulator, you will be using liquid nitrogen. It aids the freezing process instantly by spraying them to the powder suspension. You can control the granule density by the solid-state content of the powder suspension.

The good thing about this process is there can be a lesser to no cavities to the finished products. There is also a mild dying procedure that minimizes oxidation of non-oxides, and metals and with low waste material. Moreover, the process has a lower granule density, and evenly distributed pressing helps provide softer granules.

3.5 – Spray Granulator

As we know, the spray granulation is nothing but a process that helps us to use liquid for making granulates. Various industries are using this method in different applications since the product properties vary in many ways. You can do this by setting up the process parameters and configurations technically.

The heated air of the fluid bed suspends the granulated powder and the nozzles at the top spray the liquid binder. The final product is often round in shape and is suitable for making tablets.

3.6 – High-shear Granulator

The high-shear granulation method is the mixing of active powder with a solution with the use of high-speed mixing blade and chopper.

4. Production History of Pilotech Fluidized Bed Spray Granulators

Pilotech started producing laboratory spray dryer since the year 2005. It has over 50 patents and more than 15 software copyrights. Moreover, they are known in the world to be the only manufacturer that provides a wide selection of spray dryers.

Most pharmaceutical pharmacy recognizes the benefits of the fluid-bed procedure and its one-step enclosed operation.
Many users would find Pilotech’s bed spray granulator advantageous because of its stability in performance, durable service, and smooth operation. That is why researches opt for Pilotech granulator products.

5. Working Principle of Pilotech Fluidized Bed Spray Granulator

Many businesses want fluid bed granulation as their material processing technique. And several companies use it as a way of developing the dusty powder to desired granules.

These are the three stages in spray granulation:
Granulation liquid Atomization

• Particles Agglomeration
• Drying

A study of a fluidized bed granulation procedure shows that the method is the same regardless of the machine layout. It is probably because the place of fluid bed spray process is just the same. Therefore, it is perhaps the reason why others choose the high spray granulation or tangential spray process.

5.1 Atomization

It is the process of disintegrating liquid into many fine droplets, thereby yielding a high surface or mass ratio. Thus, it is possible by supplying energy to the fluid with the use of centrifugal energy, kinetic energy, pressure energy, etc.

One of the common forms of this process is the hydraulic pressure nozzle atomization. The different levels of pressure that drop across the opening delimits the droplet diameter.

5.2 Agglomeration

In this stage, you can spray the granulating liquid over the particles to initiate agglomeration. When particles contain low moisture, they can easily interact with each other and thicken fast because of liquid bridges production.

Then, droplets appear when the liquid surrounds the granule. The strength of the formed droplet is dependent on the surface pressure when in the liquid phase.

5.3 Drying

For evaporation to take place, this is the step to take when the droplets make contact with heated gas for equal distribution of fluid from the surface.

Spray Granulation is the combination of convective drying or solidification and the formation of particles in one process. By spraying liquid that contains solid onto the fluidized bed, the procedure creates compact particles. This process allows the solution to evaporate, and the particle will grow because of the remaining solid-state matters.

This method is known as layering or granulation drying because it starts with a granulation seed which is basically from the same materials when you spray the solid matter while on the liquid phase.

The seeds generate either during the process or by turning fine particles or grinding the oversized granulates from the sieving-milling circuit. So, there is no need to treat them as solid raw material.

This processing principle is a basic one that provides a significant influence on designing products and materials. It would be a great option in processing parameters to achieve the desired granulate properties. They are given below.

Process-Influencing Parameters

• Spray Liquid: It includes various aspects such as the type, the solution, suspension, etc. Moreover, other factors such as the viscosity, its composition like additives or binders.
• Spray System Design: The spray nozzle can be two- or multi-component nozzles, or pressure nozzles. Also, the nozzle orientation, i.e. at the top or bottom spray. It also includes the placement and the number of nozzles along with the droplet size and velocity.
• Processing Conditions: It includes the spray liquid temperature; the process chamber temperature; the strength of the particle movement. Moreover, it consists of the time of residence, gradient temperature, the velocity in drying or solidification.
• Machines: It could be a fluidized bed or spouted bed. The operation could be continuous or by batch, and the generation of seeds can be internal or sieving milling circuit.

6. The Main Components of Pilotech Fluidized Bed Spray Granulator

The Fluidized bed granulator has different design options. However, following the direction of Fluidization gas flow, the central part would be the following:

• Gas Plenum – It is the chamber of air or liquid
• Gas distribution – It would be responsible for the delivery of gas during the process
• Product container
• Filter bag within the chamber expansion or the expanded chamber
• Binder spray – It is usually designed with four nozzles.

7. The Main Features of Pilotech Fluidized Bed Spray Granulator

Pilotech introduces different types of fluidized bed spray granulator. The features of each equipment may vary.
Here are some of the best, unique features of Pilotech fluidized bed spray granulators:

·         Real-Time Regulation

The control technology of the PID thermostat has a real-time regulation that also adopts for temperature control. With this, you have control over the temperature when experimenting, to ensure stability throughout the process of coating and granulation. It is also useful to satisfy the demand of the users on adjusting parameters within the range of testing.

·         Dual Control System

The company designed the dual control system to limit the airflow outside and inside the guide cylinder. It would allow the user to adjust the optimum state online while the fluidization operation inside is ongoing. It still works even if there are changes in gravity that occurs while coating or granulating.

·         Convenient Operation

All types of equipment have a well-defined control system for convenient use, such as one start-up button, colored touch screen panel, and real-time modification to test the machine’s parameters. It means that it can measure air temperature, material temperature, speed, and pressure.

To guarantee stability and reliability in operating the equipment, the company brings in the high-quality core components. These core components are the control system, heater, blower, and touch screen, which has USB ports. It means that the data is transferable to a flash drive, or you may opt to print it directly online.

·         Miscellaneous Features

To meet the bulk material’s testing requirements, you may replace the container with different measurements. And to make sure they are free from contamination, the user has to put air inlet that has class 100 purification, as well as filtering devices.

8. Application Range of Pilotech Fluidized Bed Spray Granulator

The fluidized bed spray granulation is a method of producing granules that are free-flowing from its liquid form. Industries may use it in diverse applications.

Also, the features of each model of Pilotech may vary. You have the options to set the configuration and other crucial parameters. As a result, all bed spray granulator models can cover a wide range of applications. The resulting granules are suitable for producing tablets and final coating because the end product is often round.

Besides, it is also beneficial for reducing the volume of the product that minimizes transportation and storage while increasing the substance’s stability. Spray granulation in the fluidized bed allows liquids to change into a free-flowing granulate with specific properties.

9. Users of Pilotech Fluidized Bed Spray Granulator

Below are the industries that use the Pilotech’s Fluidized Bed Spray Granulators:

• Industries involved in Biomass
• Powders – It includes chemicals, catalysts, pigments, etc.
• Minerals – It consists of clays, sands, and other minerals
• Animal Feeds – It includes cereal grains, wastes, high protein, and also by-products.
• Foods – It includes starches, fruits, vegetables, etc.
• Agricultural Wastes – It includes fertilizers, animal manures, crop wastes, etc.

10. What are Different Types of Laboratory Fluidized Bed Spray Granulators of Shanghai Pilotech?

One of the leading products of Pilotech is Fluidized Bed Spray Granulator. It has three models.

10.1 YC-1000 Laboratory Granulator (Fluid Bed)

The YC-1000 laboratory spray granulator has a combination of spray drying function and fluid bed granulation. It would save the company’s expenses and experimental space since you get two functions in one machine.

Two granulation modes are available in YC-1000.

1) In the first mode, the sample is in a liquid form. Also, it has the same transport mechanism to the spray head by a peristaltic pump. Then spray over the granulation chamber under the effect of compressed air. The fluidized dextrin, which is the base material, is previously placed at the granulation chamber.

After that, atomized samples are thickened on the base materials for the granulation process and converted into the required particles.

2) In the second mode, the samples are small particles and initially placed in the cavity of the fluidized bed, and fluidized due to hot air. The binder changes it to atoms to make a bridge between tiny particles. These particles are gradually thickened to form granules based on specific requirements.

10.2 YC-03 Lab Fluidized Bed Spray Granulator

It is another fluidized bed spray granulator by Pilotech. Well, the model YC-03 and its design assure you the best performance. Moreover, the model further helps to achieve the best conditions for spray drying quickly.

YC-03 spray granulator has a spray on the top, side, and bottom. The top one has two heads which you can control online. It is the best tool that you can use for the granulation of multiple granule sizes up to the largest size, which is 6MM. The granulator also has three blowers. Each has purification functions in three levels found in line with specifications.

10.3 YC-310 Lab Fluidized Bed Spray Granulator

YC-310 is small and helpful on experimental tables. You can also install wheels on it to easily transport from one side to the other. It can accommodate 300g per batch with a top and a bottom spray. It has a fluidized bed drying function, fluidized bed granulation, and coating.

You can use YC-310 for shaping purposes which improves the powder properties. When you spray in the fluidized bed system, it changes the powder making it a free-flowing granulate with excellent solubility. This process is suitable as an initial step for making medicines tablets as well as for making cleaning agents, instant products, and drinking powders.

11. Factory Inspection of  Pilotech Fluidized Bed Spray Granulator

The company took into consideration the quality and safety when it manufactured the Pilotech fluidized bed granulators. A group of professionals comprises of engineers, designers, and manufacturers.

The fluidized bed spray granulator underwent inspection, which includes the examination of all the parts based on the drawing after completing the processing. The company also checks the spraying primer, rust preventing paint, and heat resistance paint.

These tests and inspections are indispensable to make sure that the process of spray granulator meets the standard operation within the plant area. Each company needs to have a routine checking to examine the crack on their machines.

12. Pilotech Fluidized Bed Spray Granulator – General FAQs

Below are the general questions and their answers regarding the bed spray granulators.

12.1 Why Should You Granulate Powder in the Material Processing?

Below are the benefits of granulating powder during material processing.

• It will maintain the movement and compaction
• In the manufacturing of tablets, it will improve the compressibility.
• It reduces the dust that may generate during material processing.
• Also, it is useful for the even distribution of essential ingredients.

To obtain good product quality, you need to select the right granulation procedure.
12.2 What Are the Parameters of Fluid Bed Granulation Process That May Affect the Quality of Granules?

Well, to ensure high-quality granules, it is essential to monitor various process parameters.

It is the main reason why manufacturers need to install smart control systems that can monitor the variables of fluid bed granulator. So, learning how the machine works is crucial for you to troubleshoot any issues during the process.

Most industries in the field of pharmaceutics and fluidized bed manufacturers execute the changes in relevant hardware to ensure the process controls. It also helps minimize the issues in granulation outcomes.

12.3 What Are the Fluid Bed Granulation Process Variables?

A person assigned to operate the fluid bed granulator has control over the machine. So, the operator must consider a few parameters. Adjusting these parameters can directly affect the nature of the final product.

Below are some standard parameters:

·         Fluidizing Airflow:

First in the list is a high airflow. It can cause fast evaporation, erosion, and smaller granules. So, to prevent possible clogging, you must select the right fluidizing airflow.

·         Inlet Air Temperature:

Fine granules are the result of using higher temperatures, while larger ones are due to lower temperatures. That is why this parameter is necessary.

·         The Humidity Level in the System:

The higher the humidity level, the granules tend to be dry for a longer time. In some cases, it also results in a larger size of granules.

·         Granulation Solution or Binder Spray Rate:

Fine droplet provides small granule sizes. The size of droplets depends on the flow rate of the liquid, its volume, binder viscosity, and atomizing air pressure in all fluid bed processors.

·         Binder Solution Atomization Pressure and Volume:

Ensure consistency in the mass to liquid ratio as this will help maintain the size of granulating solution droplets and the granule sizes.
For example, the droplet size increases when you keep the pressure level constant and increase the size of the orifice.

·         The Size and Position of Nozzle

The top nozzle covers the surface of the bed’s entire surface. So, when you place it closer, it provides enough fluid that results in larger granule size. On the contrary, when you put it higher and away from the bed, the process will be longer and provide you with finer granules. Some industries purchase the double nozzles equipment, so they can get the desired droplets that suit their industry.

When you analyze the process parameters of fluid bed granulation, it becomes easy for you to optimize the procedure in any laboratory.

12.4 What Are the Formulation Variables Available in Fluid Bed Granulation?

Firstly, you need to be familiar with the type and nature of materials you plan to granulate. After that, with enough knowledge, you can select the most suitable binder solution and parameters.

·         The Material Properties That You Want to Granulate

When you granulate materials, you have to consider various factors such as its density, size or shape. Moreover, other factors include the cohesiveness of the particles, the level of stickiness, fluid content, and static charges. When you understand these properties, you will be able to select the right machine for the processing of granules.

·        Properties of the Binder Solution
The use of a binder solution depends on the kind of material you want to granulate. There are a few selection granulating solutions with changing friability, porosity, mass density, size allocation, and flow rate.
You also need to look at the nature of the binder solution. Bear in mind that many solvents have diverse degrees of evaporation. You may opt for aqueous or organic solutions, depending on the nature of the process at hand. Lastly, examine the technology of the fluid bed granulation.

12.5 What Are the Variables of Fluid Bed Equipment That Affect the Effectiveness of Material Granulation?

Below are the crucial factors to consider.

Design of Fluid Bed Equipment:
The company deliberately designs its equipment to satisfy the needs of different applications. It involves the machines that are suitable for laboratory use, for R&D or pharmaceutical industries. The position of spray nozzles differs from the types of equipment. Some may find a top spray intended for granulation, and some would prefer a side spray for coating and granulation.

·        Pressure in Fluid Bed:
The quality of material fluidization depends on the pressure drop. It is the reason why you have to select the equipment that has a precise blower or fan. If you don’t have enough pressure, the fluidization time will be longer.

·        Size and Overall Design of the Air Distribution Plate:
The air distribution plate can change the degree of pressure drop. So, you must select the most suitable plate that has ample open area. Most of the time, an overlap gill plate is advisable. Also, you must use the granulation machine that has a proper shaker, granulator bowl geometry, constant blowback cycles, and even energy-efficient motors.

13. After-Sales Service at Shanghai Pilotech Instrument & Equipment Co., Ltd.

Equipment available at Pilotech contains operator interface, by default, in English. But if you wish to get one in another language, your request will be satisfied. Also, there are videos available once you purchase a product. These materials would serve as a guide for the convenience of customers to use.

Besides, the company offers a one-year warranty for all products, which will cover non-human damages.

Even though parts and materials of Pilotech equipment are of international standards and from well-known brands, some issues may still occur in some products. But it is important to note that all products have a modular configuration and you can assemble it quickly.

If you find it challenging to use the equipment, you can contact the seller anytime. And if you have concerns about the navigation and operation of the machine, the company can provide the best engineers to guide you throughout the process and tell you what to do.

Also, Pilotech can provide replacements if your unit is within the warranty period. Otherwise, the parts and accessories are readily available to purchase from your local market.

Final Thoughts!

The company aims at research and development and the stand-alone production equipment by continuous technology and installing the complete integrated production lines. We can hope for the best results in production when the company works closely with its clients for product development.

Pilotech provides you with reliable, flexible, and cost-effective manufacturing solutions that would maximize productivity and reliability in operation. For questions about the company’s products or services, feel free to send an e-mail.