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May,2020
GRANULATION
MACHINES USED FOR DRY GRANULATION AND WET
GRANULATION
GRANULATION:
Granulation, the process of particle enlargement by agglomeration technique, is one of the most
significant unit operations in the production of pharmaceutical dosage forms, mostly tablets and
capsules. Granulation process transforms fine powders into free-flowing, dust-free granules that
are easy to compress.
TYPES OF GRANULATION:
There are mainly two types of granulations namely:
Dry Granulation
Wet Granulation
Dry Granulation:
Wet Granulation:
Wet granulation involves the massing of a mix of dry primary powder particles using
a granulating fluid. The fluid contains a solvent which must be volatile so that it can be removed
by drying, and be non-toxic.
Shaban Danish 004 Dated 8th.May,2020
Slugging:
Slugging is a pre-compression process for the formation of extra large tablets (slugs), usually of
variable weight, due to poor flow of the drug powder. The resulting slugs are subsequently
broken down into granules, which are recompressed to obtain the final tablets
Explanation:
In slugging, a large tablet (slug) is produced in a heavy-duty tableting press. This mechanism of
dry granulation leads to variation in the weight of one slug to another. This variation is as a result
of the poor flow rate of powders with small particle size which in turn causes large fluctuation in
the forces applied onto the individual slugs which bring about differences of the slug’s
mechanical strength. The mechanism of dry granulation is hardly used because the properties of
the granules obtained by milling of the slugs cannot be controlled well either.
Veterinary Bolus & Slugging Heavy Duty Single Sided Rotary Tablet Press
Working:
Bolus Tablet Press Machine is used for production of simple and precise tablets from powder in
Pharmaceutical and relevant Industries.
PTCM-SH-12 is single sided rotary slugging press with square or painted round body and
suitable for small batch size production of bolus for veterinary and slugging of powder. This is a
single side rotary slugging GMP/ Standard model with rigid design, precise and simple bolus
tablet compression machine. It is heavy duty tablet press to take more press during compression.
The PTCM-SH-12 model machine is designed to enable to maximum cleanliness in operation
and accessibility, thus offering tremendous easy to operate, clean and maintenance
Salient Features :
Safety Features .
Roller Compactors:
Roller Compactors are used to force fine powders between two counter rotating rolls and presses
the raw materials into a solid compact (flakes, sheets, strips). Roll Compacters are also called dry
granulators.
Principle:
1.A feeding system, which converts the powder to the compaction area between the rolls.
2.A compaction unit, where powder is compacted between two counter rotating rolls to a ribbon
by applying a force.
3.A size reduction unit, for milling the ribbons to the desired particle size.
Shaban Danish 004 Dated 8th.May,2020
Advantages:
Disadvantages:
The Roll Compactor machine is used for increased bulk density, making granules, dust free
processing and reducing particle size of pharmaceutical ingredients in pharmaceutical industry.
The material in form of powder passes through the two counter rotating rolls of roller compactor
under very high pressure. As the volume decreases through the region of maximum pressure, the
material is formed into a solid compact sheet or flakes of ingredients. These flakes or compact
sheet of ingredients are reduced in size to obtain the desired grain size. The machine takes extra
care to prevent the generation of fine during this process.
Feeding system: This unit conveys the powder to the compaction area between the rolls.
A compaction unit: This is where the powder is compacted between two counter-
rotating rolls to a ribbon by applying a force.
A size-reduction unit: This is for milling the ribbons to the desired particle size.
Simplifies processing
Facilitates powder flow
Requires less man-hours to operate
Reproduces consistent particle density
Produces good tablet and capsule disintegration
Eliminates aqueous and solvent granulation
Improves process circle time
Shaban Danish 004 Dated 8th.May,2020
Wet Granulation:
Wet granulation involves the massing of a mix of dry primary powder particles using
a granulating fluid. The fluid contains a solvent which must be volatile so that it can be removed
by drying, and be non-toxic.
Planetary Mixer:
The planetary mixer is an industrial equipment conceived/made to prepare food, chemical,
ceramic dough or other type of product, replacing manual labour through a mechanical system
that allows to produce, continuously, large quantities of dough. They are composed by:
The name “planetary mixer” comes from the system used in the equipment that mixes the dough
in the planets rotation direction.
Salient Features:
Planetary mixer
Working:
The planetary mixer is so named because the mixing blade (commonly known as the beater)
rotates in a planetary motion inside the mixer bowl. The bowl of the single planetary mixer
consists of an upper cylindrical section and a lower hemispherical section. The mixer bowl is
secured to a semi-circular frame at the time of mixing. The beater profiles are shaped to match
the lower curved surface of the bowl. The beater has two types of movements: it revolves on it
own vertical axis at high speed. At the same time, this vertical axis rotates around the centre of
Shaban Danish 004 Dated 8th.May,2020
Oscilating Granulator:
Oscillating granulator is used for gentle homogenization, size reduction, grading and sieving of
dry, sensitive powders and granules in pharmaceutical, chemical and food industries. Oscillating
Granulator has one rotor with five edges, which oscillate on horizontal axis at about 180 per
minutes.
Working Principle:
Advantages:
Mixing and granulation are all performed within a few minutes in the same piece of equipment
Disadvantages:
The process needs to be controlled with care as the granulation progresses so quickly that a
usable granule can be transformed into an unusable over massed system, Thus it is often
necessary to use suitable monitoring system to indicate the end of the granulation process i.e.
when a granule of the desired properties has been attained.
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OSCILATING GRANULATOR
A rotor or impeller, together with a stationary component known as a stator, or an array of rotors
and stators, is used either in a tank containing the solution to be mixed, or in a pipe through
which the solution passes, to create shear.
Uses:
Working:
Fluid undergoes shear when one area of fluid travels with a different velocity relative to an
adjacent area. A high-shear mixer uses a rotating impeller or high-speed rotor, or a series of such
impellers or inline rotors, usually powered by an electric motor, to "work" the fluid, creating
flow and shear. The tip velocity, or speed of the fluid at the outside diameter of the rotor, will be
higher than the velocity at the center of the rotor, and it is this velocity difference that creates
shear.
Shaban Danish 004 Dated 8th.May,2020
Key Features:
Gral Mixer:
Working and Construction:
The angled position of the mixing blades combined with the rounded edges at the bottom of the
vessel guarantee the typical rope-type movement for optimal flow of product during granulation.
Several binder liquid spray systems are available to suit the process. Bowl and mixing blades are
shaped and mounted to minimize clearance for maximum yield, without locally overheating the
product. During a discharge cycle, the centrifugal force created by the rotation of the mixing arm
will push the product in a natural way to a proportionally regulated outlet valve at the side
without compacting the wet granules.
With capacities from 10 to 1200 liter, the Gral range can cover all requirements, from
development over clinical batch production for scale-up trials to large scale production for
marketed products.
Advanatges:
Working:
The equipment works on a principle of fluidization of the feed materials. In fluidization process,
hot air is introduced at high pressure through a perforated bed of moist solid particulate. The wet
solids are lifted from the bottom and suspended in a stream of air (fluidized state). Heat transfer
is accomplished by direct contact between the wet solid and hot gases. The vaporised liquid is
carried away by the drying gasses. Sometimes to save energy, the exit gas is partially recycled.
Construction:
Spray nozzle.
Solution deliver.
Various types of modified fluidized bed dryers have been developed and are applied in many
industrial processes to overcome some of the problems encountered while using conventional
fluidized bed dryer and for a drying process.
High potential for attrition; and in some cases agglomeration of fine particles.
The conventional hot air fluidized bed dryer is not a good choice of dryer when handling
toxic or flammable solids since there is danger of fire or explosion of flammability limits
are exceeded.
Refrences
www.pharmapproach.com
www.gea.com
www,Wikipedia.com
https://mixerworks.com/littleford-day-mixer/
www.slideshare.net
www.pharmaceuticalonline.com
www.ebseos.com
www.bplittleford.com
http://www.pharmtech.com/effect-mill-type-two-dry-granulated-placebo-formulations
https://www.brighthubengineering.com/manufacturing-technology/57871-single-planetary-
mixer/
https://pharmaceuticalmachineriesipec.com/planetary-mixer/
https://www.prismpharmamachinery.com/roll-compactor-300.html
https://www.linkedin.com/pulse/roller-compactor-basic-principles-applications-pharmaceutical-
tareq-/
https://www.saintytec.com/working-principle-pharmaceutical-roller-compactor/