Innovative Technologies for Granules and Pellets - Glatt · PDF fileInnovative Technologies...

Spray Granulation

Agglomeration

Coating

Pelletizing

Innovative Technologies for Granules and Pellets

2

E x p e r t i s e f o r a l l p r o c e s s e s

Spray granulationAgglomerationWet granulationCoatingEncapsulationInstantizingExtrusionPelletizingPowder layeringDrying

Replacing powders and liquids with

dust-free granules and pellets is the

target of many applications, in nume-

rous industries. Better product pro-

perties, easier handling, accurate

dosing and significant lower handling

hazards are advantages demanded by

the market for bulk products. By means

of functional coatings the qualities of

the granules can be influenced.

Glatt has been granulating powder in

fluid bed equipment since 1960.

Alternative technologies, like granu-

lation in the vertical granulator, pelle-

tizing, spray granulation and different

coating processes have been intro-

duced or improved by Glatt. The co-

operation with the customer is a key

issue for Glatt – the product know

how of the customer is linked with the

process and equipment know how of

Glatt. Using Glatt laboratory equip-

ment custom-designed processes are

developed for the production of new

granules and pellets. Production units

are designed based on process

parameters determined on pilot units

(scale up).

Utilizing contract manufacturing

facilities, at the Glatt company IPC,

these next generation products can be

introduced to the market even before

production sized equipment is instal-

led. Glatt knows that a couple of weeks

can be decisive for the success of a

new product.

Glatt – innovationmeets tradition

Glatt was established in 1954

in Binzen (Southern Germany)

and developed fluid bed

equipment for drying of

pharmaceutical products in the

late 1950's. Soon nozzles were

integrated into the fluid bed

making granulation and coating

processes possible.

The founding and acquisition

of new technology centres

enlarged the variety of offered

technologies:

1971:

Glatt AG in Pratteln/Switzerland

with drum coaters,

1991:

Glatt Ingenieurtechnik in

Weimar with continuous

processes and Glatt System-

technik in Dresden with vertical

granulators, pelletizer and

handling equipment.

A world wide network of sales

representatives is offering

service to our customers at their

own site, supported by process

specialists from the technology

centers.

Werner Glattand his first WSG

AGT 400, constructed in 1981 (Weimar)

3

O p t i m a l p r o c e s s e s f o r o p t i m a l p r o d u c t s

Spray granulation 4-5granules from liquids.encapsulation of liquids.

Agglomeration 6-7granules from powder.

Coating 8-9encapsulation ofparticles with liquids.

Wet granulation 10wet granulesfrom powder.

Extrusion 10/11compression ofwet granulesto extrudates.

Pelletizing 11spheronizing of wetgranules and extrudates.

Powder layering 12coating of particleswith powder.

Plant designand construction 13

Process developmentand scale up 14-15

Contract manufacturing 16

Glatt service program 17

Value added granulesand pellets from solidand/or liquid rawmaterials

C o n t e n t

Particle Productstructure example

Specific advantages usingoptimal technology• spherical pellets with a compact structure• closed surface with little abrasion• good solubility at decreased hygroscopicity• narrow grain size distribution

• excellent solubility• porous structure• good tabletting properties• wide grain size distribution

• influencing product qualities• odour or taste masking• functional coating

• compact structure• good solubility at decreased hygroscopicity• good tabletting properties• wide grain size distribution

• compact structure• good solubility at decreased hygroscopicity• good tabletting properties• wide grain size distribution

• spherical pellets with compact structures• good solubility at low hygroscopicity• smooth surface with little abrasion• narrow grain size distribution

• spherical pellets with compact structures• good solubility at low hygroscopicity• smooth surface with low abrasion• narrow grain size distribution

General advantages ofgranules and pellets• dust-free• excellent free flowing properties• good dosing properties• adjustable grain size and bulk density• good dispersibility• decreased handling hazards• mass and volume smaller compared to

liquids• no crystallization or precipitation of solutions

and suspensions

4

S p r a y g r a n u l a t i o n

Granules from liquidsSpray granulation is the drying of

liquid while simultaneously buil-

ding particle size. Seeds for the

granulation can be charged (ex-

ternal seeds). Alternatively the

seeds are formed within the pro-

cessing chamber by abrasion (in-

ternal seeds). Compared to agglo-

merates these granules are har-

der and more dense. The spray

granulation process was develo-

ped in the early 1980's at what is

now Glatt Ingenieurtechnik.

Since that time Glatt is one of the

leading suppliers of this techno-

logy.

Adding solid raw materialsIf solids are added to the spray

granulation process they are inte-

grated into the onion structured

granules. Adding more and more

powder shifts the spray granulati-

on process towards agglomerati-

on. It is also possible to form small

granules from the liquid raw ma-

terial which are agglomerated to

larger particles in the same pro-

cessing chamber.

„onion“ structure

spraying spreading solidifying final granule

solidified shellsprayed droplet seeds/powder

instant-tea – ideal agglomerate

lysine – hybride

detergent component – ideal spray granule

Ideal agglomerates and ideal spray

granulates are the two extremes of

a continuous scale. By changing the

process parameters both processes

occur simultaneously and form diffe-

rent structures. Since agglomerates

have a smaller bulk density than

spray granulates the bulk density of

the granules is adjustable.

droplets encapsulated in a spray granule

ceramic,spray granulate

Product properties• dust-free granules

• spherical pellets

• excellent free flowing properties

• good dosing properties

• good dispersibility

• good solubility

• compact structure

• decreased hygroscopicity

• high bulk density

• closed surface

• narrow grain size distribution

• little abrasion

Encapsulation of liquidsMixing different liquid raw materials

before spray granulation they will be

very evenly distributed in the granules.

By this means liquids can be encapsu-

lated into a matrix of solid material.

Sensitive substances ar well pro-

tected.

This encapsulation process is mainly

applied in the food industry. If nece-

sary the particles can be finally encap-

sulated with a secondary coating (refer

to page 8 – Coating).

|<– 1 mm –>|

5

0 200 400 600 800 10000

20

40

60

80

100

spouted bed granulator – ProCell 25, pilot plant

principle ofcontinuous spray granulation process – GFG

fluid bed granulator – AGT 2700

principle ofcontinuous spray granulation process – AGT

analysis of particle size – GFG 500 – adjustablegrain size of sodium phosphate

product no. 1

product no. 2

product no. 3

product no. 4

product no. 5

on s

ieve

[%

]

particle size

principle ofcontinuous spray granulation process – ProCell

S p r a y g r a n u l a t i o n

ProCell – spouted bedIn the ProCell the process air enters

the processing chamber through a slot.

By this means very small particles can

be generated (product particle size

of 50 m). When processing sticky

materials the high air velocity in the

slot prevents lumping. Compared to

the fluid bed, the residence time can

be decreased resulting in a very gentle

process for temperature sensitive

materials.

GPCG, AGT and GFG – fluid bedFor small quantities the process can

be run in batch mode in the GPCG.

The undersized particles of the pre-

vious batch are screened off and used

as starting material (also refer to page

9 – Wurster).

Continuous processes are more effi-

cient since they can be run with a

constant bed height in the processing

chamber. According to the process

the entire fluid bed is mixed and the

product is discharged through a cen-

tral discharge pipe (AGT-process), or

a plug flow is created in the GFG.

Using the GFG, drying and cooling of

the granules can be accomplished in

the same equipment as in the agglo-

meration process.

fluid bed granulator – GFG 1200

6

A g g l o m e r a t i o n

„raspberry“ structurebinder droplets powder solid bridgesliquid bridges

final granule

Granules from powderAgglomeration in the fluid bed

has been used for a long time to

form granules from a powder. The

fluidized powder is wetted until

liquid bridges are formed

between the particles. Water,

solutions, suspensions or melts

can be sprayed to meet the

desired product quality.

Using this technology the amount

of dust is decreased, the

flowability and the dispersability

in water are improved.

Segregation of powder mixtures

do not occur since the different

powders are glued together on a

micro-scale. Since the impinging

forces in the fluid bed are small,

weak granules are formed with

an excellent solubility (instant

products). Spraying more binding

liquid results in stronger granules

(also refer to page 4 - Adding solid

raw materials).


• good free flowing properties



• excellent solubility

• porous structure

• good tabletting properties

• low bulk density

• wide grain size distribution

wettingspraying

tomato,agglomerate

Immobilization of liquidsThe agglomeration process can also

be used as an immobilization process

for liquids. A powdery adsorbent is

used as a carrier and saturated with

the liquid. The product is a liquid inte-

grated into a dry, free flowing agglo-

merate. This process is also called

encapsulation.

|<— 1 mm —>|

solidifying

7

fluid bed granulator – GFG 850

principle of continuous agglomeration process – GFG principle of batch agglomeration process – WSG

fluid bed granulator – WSG PRO 120

WSG – batch fluid bedThe process steps in the continuous

unit are seperated in zones. In the

batch unit they are separeted by

time. Powder is charged into the pro-

cessing chamber of the fluid bed

granulator (WSG). In the first process

step the fluidized powder is wetted

until agglomeration occurs. As soon

as the desired grain size is reached,

spraying is stopped and the granules

are dried. Frequently the product is

cooled before discharge.

The granules are discharged, the next

batch can start.

single arm nozzle with six heads

GFG – continuous fluid bedPowder is fed continuously into the

processing chamber. In the first part

of the chamber liquid is sprayed into

the bed and the powder is agglome-

rated. The wet granules are dried and

cooled in the following parts of the

processing chamber. The different

processes are determined by diffe-

rent process gas qualities in different

inlet gas chambers. If necessary the

processing chamber can be separated

into zones by weirs.

A g g l o m e r a t i o n

8

C o a t i n g

GPCG, AGT and GF – fluid bedWhen coating in the fluid bed the par-

ticles are fluidized and the coating

liquid is sprayed into the bed while

drying the particle. No over-wetting

is allowed in order to prevent agglo-

meration of the particles. For many

applications this technology is suffi-

cient. A complete coverage of the

particle surface requires a lot of

coating material. Depending on the

throughput, batch or continuous

units can be used.

Coating and encap-sulation of particleswith liquidsParticles are coated in order to

change their surface properties

and by this means the behavior

of the particles. Glatt offers dif-

ferent processes for the coating

of different particles. This equip-

ment choise allows the customer

to choose specific levels of

coating quality.

The coating liquid can be a solu-

tion, suspension or melt. In all

processes the coating liquid is

sprayed onto the particles. Low

viscosity and small droplets are

required to ensure even sprea-

ding of the coating liquid on

the surface of the particles.

fluid bed coater – GFC 750

principle of continuous coating process – GFC

coating droplet particle

spraying wetting spreading coated particle

fluid bed coater –GPCG 30

principle of batch coatingprocess – WSG/GPCG

fertilizer,uncoatet

fertilizer,coatet

Defined alteration ofproduct properties• stability in storage

• hygroscopicity

• free flowing property

• surface structure

• solubility

• appearance

• taste

• odor

|<— 1 mm —>| |<— 1 mm —>|

9

C o a t i n g

GPCG, WS Combo –Wurster-coatingThe Wurster process allows a 100%

coating with small amounts of coating

material. The particles in the fluid bed

are passing the bottom spray nozzle

in an ordered flow pattern. While

quickly moving upwards within the

Wurster compartment they can be

wetted without the danger of agglo-

meration. While moving downwards

outside the Wurster compartment

they dry and another layer of coating

can be supplied. The exactly control-

led residence time in the coating zone

ensures a very uniform coating.

GC – drum coatingUsing the drum coater large particles

(e.g. tablets) can be coated with a high

quality film. The particles are moved

by means of the rotating drum. The

coating liquid is sprayed into this bed

of material. The particles are dried by

means of an airflow through the

perforated drum.

ProCell – spouted bedCompared to the fluid bed, the resi-

dence time in the ProCell is shorter,

improving the continuous process

for temperature sensitive product.

Also irregular particles (e.g. ceramic

catalyst rings) can be coated since

they are moved by the high air velocity

in the slot.

Small particles can be coated without

agglomeration, which is prevented by

the high velocity of the particles. Small

particles have a large specific surface,

which is requiring larger amounts of

coating material.

coating drum GC

principle of drum coating process – GCprinciple of batch coating process – Wurster insert

processing chamber GPCG 200 Wurster insert

principle of continuous coating process – ProCell

processing chamber ProCell

10

W e t g r a n u l a t i o n

Wet granules from powderPowder is charged into the product

bowl of the wet granulator and wetted

by heavy spraying of a liquid or a melt.

At the same time the product is

vigorously mixed by a mixer and a

chopper. Since the powder is physi-

cally forced together the agglomerates

formed in this process are harder and

more dense than in the fluid bed agglo-

meration process. In many cases the

granules are discharged into a cone

mill to crush oversized particles before

they are dried or cooled in a fluid bed

dryer (WST).

Vertical granulator (VG) and top-

drive granulator (TDG) operate in

batches. With the continuous granulator

(GCG) a continuous wet granulation is

possible. In the fluid bed dryer (GFT)

the granules can be continuously dried.





• good solubility

• good tabletting properties





principle of continuous basket extrusionprocess – GBE

principle of batch wet granulation process – VG

basket extruder – GBE 600wet granulator – TDG 100

vitamine,wet granules

vitamine,extrudates

spraying solidifying final granule

powder solid bridgesliquid bridges

wetting

binder droplet „snowball“ structure

granules

„snowball“ structure

11

E x t r u s i o n P e l l e t i z i n g

Spheronizing of wet granulesand extrudatesIrregular granules and extrudates may

be spheronized with the Pelletizer (P).

The fast spinning pelletizer disk for-

ces the granules to the rim of the disk

and at the same time into the spinning

direction. This results in a rolling

movement of the granules in two

dimensions – similar to a helix.

This intense rolling is smoothing the

surface – ideally, spherical pellets

are the result. The final particles are

dried in a fluid bed dryer.


• round pellets




• good solubility




• closed surface

• narrow particle size distribution

• little abrasion

• attractive appearance

Compression of wet granules to extrudatesIn a low pressure extruder (GBE) wet

granules are formed into small rods.

The wet granules are pressed through

a die by means of two countercurrent

mixers. The granules are further com-

pressed. Usually the extrudates are fed

to a pelletizer, where they break into

pieces. The diameter and the length

of these pieces are similar. In the pel-

letizer the surface of the extrudates is

made smoother and the edges are

taken away. Extruder, pelletizer and

fluid bed dryer operate continuously.

If desired pelletizer and dryer can also

operate in batches. In this case the wet

extrudates are collected to the desired

batch size before the pelletizing step.





• good solubility





pelletizing plate P 180

vitamine,pellets

vitamine,pellets

principle of spheronizing process, continuous or batch

granules/extrudates spheronizing pelletsbreaking up

extrudates

long rods

„snowball“ structure

long rods

12

P o w d e r l a y e r i n g

Coating of particles withpowderThis process is a combination of the

fluid bed and the pelletizer. Seeds are

charged onto the rotor disk and moved

by the spinning of the disk and the air

flow through the gap at the wall of the

process chamber. Powder and binding

liquid is sprayed tangentially into this

bed of material. The powder is rolled

up to the seeds, the rolling movement

ensures spherical particles. The air

flow at the wall is drying the pellets.

It is also possible to add several layers

of powder onto the seeds within one

batch. After building the first layer the

pellets are dried and the next layer is

added with its specific binder etc.


• round pellets




• good solubility




• closed surface

• narrow grain size distribution

• little abrasion

• attractive appearance

principle of powder layering – Rotor

rotor-granulator – GRG 30

sugarand starch,pellets

ProCell LabSystem with Rotor-300 system

spraying drying/solidifying pellet

seed binder droplet solid bridgesliquid bridges

rolling up

powder

process chamber rotor insert GPCG Plus 120

|<— 1 mm —>|

500

3300

2600

600

600

600

900

2000

Iso200 Iso200

500

400

3400

1200

1600

1600

A

90007800 80

50

Iso200650

130013001300130013001300400

650 650 650

1200

13

P l a n t d e s i g n a n d c o n s t r u c t i o n

Glatt designs and constructshigh quality plants forcustomers in all industriesPlant construction has been the core

business of Glatt since more than 50

years. The experience in design and

manufacturing results in high reliabi-

lity and convenient operation of Glatt

equipment.

Usually all equipment necessary for

the process are delivered by Glatt –

pumps, fans, inlet air and exhaust treat-

ment as well as the control system.

Further equipment can be delivered

by Glatt – upstream or downstream of

the Glatt unit – up to the delivery of a

turnkey plant including the building.

Glatt equipment is installed by in-

house personnel, thus insuring that the

project is handled with Glatt know how

until the handover of the fully operating

plant.

continuous spouted bed granulator – ProCell 500

14

200 400 600 8000 1000

1.0

2.0

3.0

1.4.

0.2

P r o c e s s d e v e l o p m e n t a n d s c a l e u p

A difficult task is aninteresting challengeProcesses and formulations can be de-

veloped in Glatt technology centers.

Trials are frequently needed in order

to adjust process and equipment to the

specific requirements of the customer.

Decades of experience are the basis

for successful process optimization.

Processes are established in labora-

tory units at a small scale of 1-2 kg.

In the next step optimal parameters

for the production size equipment

are determined using scale up units

(50-200 kg per batch or per hour). The processes are developed in close

cooperation with the customer. The

product know how of the customer and

Glatt's know how of process and

technology are combined to meet the

requirements of the new product.

Understanding the potential of the

different granulation processes helps

the customer to use all possibilities to

achieve the right qualities and develop

the next generation product.

continuous spouted bed/fluid bed pilot unit ProCell/GF 25

fluid bed lab unit Mini-Glatt

fluid bed lab unit GPCG 2

lab pan coater Mini-Coater

batch fluid bed pilot unit GPCG 15

pelletizer lab unit P 50

transportvelocity

fluidizingvelocity

air velocity [m/s]

particle size

region ofoperation

ρM = 0.8 t/m3

t L = 100°C

15

P r o c e s s d e v e l o p m e n t a n d s c a l e u p

optical analysis

Analytical laboratories withadvanced equipmentGlatt technology centers are equipped

with state of the art analytical instru-

ments to determine product properties

• Analysis of product properties such

as particle shape, particle size

distribution, abrasion, bulk density,

moisture, pH-value, conductivity,

aroma/oil content

• Zeiss microscope Axio Scope A1:

optical inspection of particle shape

and size as well as consistency of

suspensions and emulsions

• CILAS 1190 LD: graphical image

evaluation of particle shape and

size, dry or in suspension

• Q 600 SDT: thermal analysis by

real/time measurement of mass

change (TGA) and heat flow (DSC)

• VTI-SA: precise determination of

water and steam sorption isotherms

with continuous operation

• determination of droplet size

• further analytical instruments on

customer request

determination of sorption isothermal

lab unit ProCell LabSystem with process insert GF 3

particle size analysis

Q 600 SDT

Cilas 1190 LD

16

C o n t r a c t m a n u f a c t u r i n g

Access to the technologies ofthe future

Faster market launches

Time to the market is the key for the

success of new products. Until the new

Glatt production equipment is installed

the newly developed products can be

produced at the Glatt company IPC.

The latest Glatt technology is imme-

diately available for our customers.

If the demand of the market does not

require new production facilities, in-

stalled equipment runs at full capacity

or the market shall be tested with

product samples – contract manufac-

turing is the answer.

flexible fluid bed/spouted bed unit GF/ProCell 250 with WIP filter

GPCG 200 with nitrogen closed loop

charging the Bag-in-Box

finished goods storage GPCG 300, open

raw material dosing and product screening

1717

G l a t t s e r v i c e p r o g r a m

The single source

Glatt equipment

Fluid bed and spouted bedequipmentas dryer, with spraying system as

granulator, with Wurster insert for

coating, with rotor insert for powder

layering.

Pan coatersfor film coating of tablets.

Wet granulatorsfor wet granulation of powders.

Extrudersfor compression of wet granules into

extrudates.

Pelletizersfor spheronization of extrudates.

Sievesfor reducing of oversized granules to

a defined grain size.

Product handling systemscontainers, container blenders, lifting

systems, transport and pneumatic

conveying systems, filling and dis-

charging systems, docking systems,

isolation flap systems, component

weighing systems, dosing systems,

washing systems, validation and

documentation.

Engineering and services

Product developmentGlatt technology centers and

laboratories for the development and

optimization of your products.

Process development andoptimizationGlatt optimizes the process for your

product and determines the process

parameters at pilot plants.

Process and plant engineeringGlatt engineers and commissions

production lines up to turnkey projects.

Assembly, installation, start-upGlatt realizes new plants and retrofits

with in-house personell.

Qualification and validationGlatt supplies all documents needed

for a comprehensive qualification and

validation of the equipment.

In addition, Glatt supplies qualification

and validation services for the equip-

ment of other suppliers and their pro-

cesses.

Contract manufacturingGlatt offers toll manufacturing with

Glatt equipment.

TrainingGlatt offers courses on specific

subjects and organizes individual

training programs.

A d d r e s s e s

World wide service to the customer

Glatt GmbH Process TechnologyWerner-Glatt-Strasse 179589 Binzen/GermanyPhone: +49 7621 6 64 0Fax: +49 7621 6 47 23eMail: [email protected]

Glatt Air Techniques Inc.20 Spear RoadRamsey, NJ 07446 USAPhone: +1 201 8 25 87 00Fax: +1 201 8 25 03 89eMail: [email protected]

Glatt Maschinen- & Apparatebau AGKraftwerkstrasse 64133 Pratteln 1/SwitzerlandPhone: +41 61 8 26 47 47Fax: +41 61 8 26 48 48eMail: [email protected]

Glatt Systemtechnik GmbHGrunaer Weg 2601277 Dresden/GermanyPhone: +49 351 25 84 0Fax: +49 351 25 84 328eMail: [email protected]

IPC Process Center GmbHGrunaer Weg 2601277 Dresden/GermanyPhone: +49 351 25 84 0Fax: +49 351 25 84 328eMail: [email protected]

Glatt Ingenieurtechnik GmbHMoskau/Russiaул. Обручева, 23 - корп. 3

117630 Москва/Россия

Phone: +7 495 78742-89Fax: +7 495 78742-91eMail: [email protected]

Glatt Pharmatech SASUParc Technologique6, rue Louis Néel21000 Dijon/FrancePhone: +33 3 80 74 32 64Fax: +33 3 80 74 43 95eMail: [email protected]

Glatt Protech Ltd.Swannington Rd. Cottage Lane Ind. Est.Broughton AstleyLeicester LE9 6TU/Great BritainPhone: +44 1455 28 58 58Fax: +44 1455 28 55 10eMail: [email protected]

Glatt Ingenieurtechnik GmbHNordstrasse 1299427 Weimar/Germany

Phone: +49 3643 47 0Fax: +49 3643 47 12 31eMail: [email protected]

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