1. General description of Fluid Bed Granulator
FL series fluid bed granulator is a batch type top spray powder granulation/ agglomeration processor which has been widely used in foodstuff, chemical, feedstuff, health products industry and so on.
It combines the functions of mixing, granulating and drying in one body, so it is also called one step granulator.
Pictures of Fluid bed granulator
2. Work principle of Fluid bed granulator
Raw material (free-flowing dry powder or small granules) is loaded in the granulating bowl of which the bottom is made by perforated plate. Clean hot air flows through the perforated plate to completely fluidize the material. Meanwhile, liquid binder is sprayed onto the fluidized material. Fine powder collides with droplets and stick together to form granules or agglomerates with good flowability and instant solubility.
Granules that made by fluid bed granulator
3. Features of Fluid bed granulator
1. Mixing-granulating-drying in one step
2. Adopting double chamber filter bags system, it can remove dust completely. The bag is made of anti-static filter cloth, so the operation is safe.
3. Through powder granulating, the flow property is improved and the dust is reduced.
4. The unique design of the nozzle can meet the granulating requirements of the products with different characteristics.
5. Designed, manufactured and laid out by GMP
6. Can choose 2 bar explosion-proof design.
Flow chart of Fluid bed granulator
4. Technical advantages of Fluid bed granulator
4.1. cGMP Design: 150 grit exterior finish, mirror finish on internal surfaces. The system can meet GMP standard;
4.2. HEPA air filter: The air filter consists of primary stage, secondary stage and high efficiency stage air filter and the air cleanness can reach 100,000 grade;
4.3. Automatic pneumatic sealing: Two pneumatic cylinders lift the granulation bowl for sealing with the top chamber; the inflated square rubber ring will seal the bottom chamber to create a completely sealed granulation chamber;
4.4. Two-bag-filter-chamber system: The top bag filtering system has two chambers which work alternately to avoid air pressure onto the filter bag. The product rate can reach 99%.
4.5. Accurate air flow control: The exhaust fan is combined with inverter to accurately control the air flow rate for achieving perfect fluidization.
4.6. Good working condition: The whole system is working under negative pressure, so there is no powder leaking at all. Exhaust fan is equipped with silencer as well as isolated installation, the noise is below 75 dB(A).
4.7. Safety measures: The whole system adopts following measure to 100 % make sure safety during operation:
1) Function interlocked: All the function buttons in the control panel are interlocked (only proper operation steps can run the system to prevent any mistakable operation to the machine.
2) Explosion proof design: Granulation chamber is equipment with venting. When the pressure inside the chamber is getting higher than the rated one (say 2 bar), the rupture membrane will break to release the pressure.
3) Pressure monitoring: Pressure sensor is equipped to monitor pressure change inside the granulation chamber. When pressure is getting higher (especially when the bag filter is choked) and positive pressure condition is formed, electrical heater and exhaust fan will stop automatically and pressure release valve will open.
5. Structure of Fluid bed granulator
Fluid bed granulator consists of air filter, heating, inlet air pipe, air distribution chamber, fluid bed, fluidized chamber, dust remove chamber, peristaltic pump, spray nozzle, exhaust air pipe, exhaust fan, silencer and control cabinet.
3.1. Air filter of fluid bed granulator:
Filter includes primary, middle and high efficient filter (HEPA filter). It can make sure the purification achieves 100000 degrees. And there is a meter that can show the pressure differential before and after the high efficient filter, so we can know the resistance in time.
3.2. Heating system of fluid bed granulator:
In general, the heating source is steam, thermal oil or electricity. So the heating system is heat exchanger or electricity. The heating system uses PID technology to ensure that the temperature fluctuation range is controlled within ±2℃. To ensure dried material is cooled timely, a cooling system is optional to achieve online cooling function.
3.3. Main machine of fluid bed granulator:
3.3.1. The main machine is 20% higher than the conventional design, making the machine has a wide processing range. It can granulate and dry different materials, and it can ensure the definite fluidized height so that the load of bag dust collector is reduced. The bag dust collector can remove dust continuously when the dryer is working. We can set dust remove time and interval time, so the dust removing efficiency and fluidized efficiency is good. The bag is static-free type, the static electricity appears during the drying process can be eliminated, so the material is not to stick on the bag. There is differential pressure display device for the bag, so we can clean or replace the bag in time.
3.3.2. The equipment is round sealed structure, there is no dead angle. So it is convenient to clean the machine and there is no cross contamination, and confirms GMP requirements.
3.3.2. The air distributing plate is special designed, air is well-distributed, material fluidized efficiency is good. Perforated plate is quick-install type, it is convenient to clean and maintain.
3.3.3. There is negative pressure feed device, labor intensity is reduced.
3.3.4. Adopts air cylinder type sealing and air bag sealing structure, seal is stable and operation is easy.
3.4. Exhaust air system of fluid bed granulator
It consists of exhaust air pipe, exhaust fan and silencer. Exhaust fan and main machine are installed separately, and the noise is ≤75dB. The rotary speed of exhaust fan is regulated by inverter, so it is convenient to adjust the air volume for different materials.
3.5. Spray system of fluid bed granulator:
The spray system consists of a top spray gun, a precision peristaltic pump, and a liquid tank. It melts and mixes the binder or slurry to ensure effective atomization and meet the granulation requirements, ensuring qualified finished products
3.6. CIP online cleaning system of fluid bed granulator:
The main machine is equipped with an online cleaning device, which allows users to connect to the pipeline of the online cleaning system for online cleaning. The bottom of the main machine is equipped with a sewage interface, which can quickly drain any accumulated water or solution during cleaning process.
3.7. Control system of fluid bed granulator
Control system is PLC & Touch screen type, operation is convenient and stable. There is strict interlock function, so there will be no incorrect operation. There are temperature and pressure measure and display devices, inlet air temperature is controlled by PID control technology.
4. Parameters of Fluid bed granulator
| Model | FL-3 | FL-5 | FL-15 | FL-30 | FL-60 | FL-90 | FL-120 | FL-200 | FL-300 | FL-500 |
| Volume of container (L) | 12 | 22 | 45 | 100 | 220 | 300 | 420 | 670 | 1000 | 1500 |
| Capacity (kg/batch) | 3 | 5 | 15 | 30 | 60 | 100 | 120 | 200 | 300 | 500 |
| Power of fan (kg) | 3 | 4 | 5.5 | 7.5 | 11 | 18.5 | 22 | 30 | 37 | 45 |
| Steam consumption (kg/h) | 15 | 23 | 42 | 70 | 141 | 180 | 211 | 282 | 366 | 451 |
| Pressure of steam (Mpa) | 0.3~0.6 | 0.3~0.6
| 0.3~0.6
| 0.3~0.6
| 0.3~0.6
| 0.3~0.6
| 0.3~0.6
| 0.3~0.6
| 0.3~0.6
| 0.3~0.6
|
| Consumption of compressed air (m3/min) | 0.6 | 0.9 | 0.9 | 0.9 | 1.0 | 1.0 | 1.0 | 1.1 | 1.5 | 1.5 |
| Working temperature (℃) | 40~120 | 40~120
| 40~120
| 40~120
| 40~120
| 40~120
| 40~120
| 40~120
| 40~120
| 40~120
|
| Working time (min/ batch) | 45~90 | 45~90
| 45~90
| 45~90
| 45~90
| 45~90
| 45~90
| 45~90
| 45~90
| 45~90
|
| Product collecting rate | ≥99% | ≥99%
| ≥99%
| ≥99%
| ≥99%
| ≥99%
| ≥99%
| ≥99%
| ≥99%
| ≥99%
|
| Weight of machine (kg) | 500 | 700 | 900 | 1000 | 1100 | 1200 | 1300 | 1500 | 1800 | 2000 |
| Size of output granules (mesh) | 40~100 | 40~100
| 40~100
| 40~100
| 40~100
| 40~100
| 40~100
| 40~100
| 40~100
| 40~100
|
| Moisture of output granules | ≤1.5% | ≤1.5%
| ≤1.5%
| ≤1.5%
| ≤1.5%
| ≤1.5%
| ≤1.5%
| ≤1.5%
| ≤1.5%
| ≤1.5% |
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