Granulation & Drying Processes

Built-in process versatility
GEA Pharma Systems is in the unique position to have in-house experience with all commonly used wet granulation methods. Therefore, at the GPS Technology Centre you can test your material in a fluid bed spray granulator, top or bottom drive high shear granulator with fluid bed drying, with all tests being made in development, pilot scale plant or small scale production, depending on your needs.

At the GPS Technology Centre we can handle product volumes: 20 g to 100 kg

Fluid Bed Processing

Available Plant Scale Batch Size
MP Micro™ Development 20-200 g
STREA-1™ Development 0.2-2 kg
MP-1 Development 0.2 -6 kg
MP-2/3 Pilot 1-30 kg
MP-4/5 Small-scale Production 30-100 kg

Fluid bed processes supported at the GPS Technology Centre:

Top Spray Granulating
The top spray granulator agglomerates finer particles into larger, free flowing granulates in a one-pot process. Ingredients are mixed and pre-heated by an upward flow of heated air. Granulation occurs by spraying liquid into the fluidized powder. The granules are subsequently dried with heated air. The top spray granulator can also be used for top spray coating, layering from liquids, and instantizing.

Special features:

  • One pot process

Spray Dryer Granulating
The spray dryer granulator transforms suspensions or solutions into dry, free-flowing, dustless granules. A suspension or solution of the substance to be dried is sprayed onto warm air, simultaneously drying and agglomerating the product. Batch or continuous discharge is available - in the continuous mode, the product is discharged at a controlled rate to maintain an optimum bed height.

Special features:

  • Compact unit 
  • Easy scale-up
  • Batch or continuous discharge

Precision-Granulating™
A rotating high velocity air stream is established in the central agglomeration tube. Particles are picked up at the base of the tube and accelerated by the air stream. The particles come into contact with liquid droplets produced from the spray nozzle at the base of the tube \ the relative velocity of air, liquid droplets and particles are high so wetting is efficient and drying begins almost immediately. Most of the feed material is in the outer “holding area”, where the gas velocity is very low. Attrition is greatly reduced. The gas humidity is also low in the holding area so the material is dry not sticky. Individual particles may make repeated cycles (typically from 10 to 1,000) through the tube, allowing very large agglomerates to be built up.

Batch Fluid Bed Drying
When drying fine wet solids in a fluid bed the speed of the air flow supports the particles and transforms them into a fluid-like state. Once in this state, the external surface of each particle is exposed to the heated moving air which creates a heat and mass transfer. Heat is transferred to the particles in order to evaporate the liquid and mass is transferred as a vapour into the moving air. Heat transfer in a fluid bed dryer takes place by convection which is the transfer of heat from one point to another. This has the effect of removing the solvent from the particles and exhausting the moisture laden air away from the product container. The air used to fluidise the product bed is normally heated so that the heat transfer process is very rapid. Batch drying time and good fluidisation are controlled by the inlet air temperature and the air flow volume. The higher the inlet air temperature, the greater capacity it has to hold vapour. The correct level of air flow volume will maintain the fluid state of the product bed and minimise any attrition.

Special features:

  • Selection of air distributors
  • Short process time

Process Integration

Current Good Manufacturing Practices increasingly require that product is fully contained during processing to protect operators and environment. Integrated process systems not only offer containment but improved productivity through automation, increased yield and efficient cleaning procedures.

At the GPS Technology Centre we are uniquely qualified to demonstrate state-of-the-art integrated High Shear Mixer Granulator and Fluid Bed Drying. Drawing on the world class expertise of GEA Pharma Systems companies, you are able to utilize our fully integrated turnkey installations including fluid bed process equipment combined with Top- and Bottom-drive High Shear Mixer-Granulators from Aeromatic-Fielder™ and Collette™.

Contact:
GEA Pharma Systems AG
GPS Technology Centre
PO Box 112, Hauptstrasse 145
CH-4416, Bubendorf, Switzerland
Tel: +41 61 936 37 00 Fax: +41 61 936 37 30
tc@geapharmasystems.com

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