The SHAKTI Fluid Bed Processor & Coater GMP Model offers an effective and efficient method for drying, granulating, coating and agglomerating. It is invented keeping in mind the latest GMP norms with all contact parts AISI 316 Quality. By using modular construction and simplified design, we provide flexible installation. The Machine is vertical type, Steam Heated, Electrical controls Auto Mode, Arrangement for spraying an active ingredient on to the carrier bed for top spraying, Explosion proof and suitable for efficient accurate and uniform drying wet granulated pharmaceutical solid powder at lower temperature.
It works on the principle of air flow. The process is as follows.
Step 1 : Mixing Dry mixing by fluidizing the material in the machine.
The Fluid Bed system have a bed of solid particles which are fluidized by passing a stream of air upward through a specially designed perforated sheet. The upward velocity of air is so maintained so as to slightly lift the solid particles and set them in motion. This motion can be utilized to bring about mixing as well as forward movement of the solids particles. The air is heated and the process hot air evaporates the fluid and dries the solids. Fines get agglomerated to larger granules particles thus providing large size.
Step 2 : Agglomeration / Granulation with TOP SPRAY
Mixed powder is build up into powder granules. The fluidized powder is wetted with binders using top spray guns (Top spraying system). Solvent or water is used for binders. The moistened granulates are dried using hot air and cooled as required.
TOP-SPRAY / DRYER insert for processing.
A. AGGLOMERATION / GRANULATION
- Reduce fines / dust.
- Enhance flow ability.
- Eliminate segregation.
- Homogeneous mixture of ingredients.
- Increase bulk density.
- Improve disintegration.
- Improve dissolution.
- Improve compressibility for tablet formation.
This process is used in fluid beds to form granules from a fine powder. The fluidized powder is wetted with binders using top spray guns. Solvent or water is used for binders. The fluidized powder is wetted until liquid bridges are formed between particles Segregation of powder does not take place as different powder is glued together on a micro scale. Since there is no impinging force in fluid bed, equipments using hot air. This technology used for formed granules are dust free granules with free flow properties, good dispensability and excellent solubility due to porous structure.
GRANULATION & AGGLOMERATION by TOP SPRAYING SYSTEM:
PALLETS COATING BY BOTTOM SPRAYING SYSTEM (WURSTER COATING):
This processing option uses the energies and controls of the fluid bed to create a pneumatic mass transport inside a special insert, which consists of a perforated bottom screen with defined free areas. Most of the process air is channeled through the center via a tube, as such producing a venturi effect, which sucks the product from outside the partition past the spray nozzle. Leaving the cylindrical partition and entering the conical expansion chamber the particle velocity is dramatically reduced, excess moisture is rapidly evaporated with the dry product returning repeatedly through the coating zone to receive more coating material. This uniform statistical residence time of all particles in the coating zone results in a very homogenous coating. Due to the high kinetic energy provided by the pneumatic mass flow moist particles are separated, as such allowing the individual coating of even very small particles. Due to the nozzle being positioned directly inside the product and concurrently spraying, a premature viscosity change of the coating droplet is avoided. All this features result in the highest possible coating quality, which is imperatively required to produce defined and reproducible drug delivery profiles.
- Design confirms cGMP Norms.
- Contact parts in SS 316 and non-contact parts SS 304.
- Single Pot Technology for mixing, granulating, drying, & blending.
- Yield approaching 100% with negligible handling losses due to single pot concept.
- Replaces a number of conventional machinery, resulting in Substantial Savings in Space, Power, Manpower, Yield and Air conditioning costs.
- Shorter cycle time.
- Ease in Validation.
- Highest Degree of Safety.
- Sampling Port facilitates withdrawal of any number of samples for In-process Quality Control tests, without interrupting the fluidization process.
- Top spaying system with precise flow control peristaltic pump.
- Spraying flow rate controlled by Peristaltic pump manually.
- Spraying nozzle 1 mm size.
- Inlet Air system with filter and electric heater.
- Airflow control by A C Frequency Drive for Exhaust Blower.
- Machine is with emergency stop button.
- Automated filter beg shaking system.
- Sight Glass for process visualization.
- Air pressure controls switch for safety.
- Exhaust air suction turbine blower 90 cfm capacity fitted with 2 hp / 0.75 Kw with single phase power supply.
- All rubber seal made from silicon food grade.
- Easy mechanism to change from process of granulation to coating.
- OPTIONAL – (EXTRA COAST)
- SCADA , LAPTOP/ DESK TOP , PRINTER Attachments.
Technical Specifications of SFBP-Fluid Bed Processor – 1 To 5 Kg. – PLC With Top & Bottom Spraying System
|MODEL||SFBP - 1||SFBP - 2||SFBP - 3||SFBP - 5|
|Container Volume in Liters||2 Liters||4 Liters||8 Liters||12 Liters|
|Batch Capacity in Kg |
at 0.5 bulk density
|500 GM. To 1 KG||500 GM. To 2 KG||1 TO 3Kg||1 TO 5Kg|
|Drying Temp in ° C||50-60||50-60||50-60||40-85° C|
|Motor in HP||1 HP/ 3 ph / 50 Hz.||2 HP/ 3 ph / 50 Hz.||2 HP||3 HP|
|VFD||3 HP VFD|
|Air Flow for inlet air (m³/hrs) ±10%||60 CFM||60 CFM||150 CFM||270 CFM|
|Heating Load Kw For Electric Heated||2 Kw||2 Kw||8 Kw||10 Kw|
|Electrical Load / Supply||440 / 220 volts, 3 phase, 50 / 60 Hz.||440 / 220 volts, 3 phase||9 Kw / 440 v / 3 Ph / 50 Hz|
9 Kw / 220v / 3 Ph / 60 Hz
|440 v / 3 Ph / 50 Hz
220v / 3 Ph / 60 Hz
|Approx air consumption m³/hour |
(Air pressure 4 Kg/cm²)
|100 m³/hour||100 m³/hour||23 m³/hour||460 m³/hour|
|Spraying Nozzle-Top Spray||1 No. with 1 mm size tip.||1 No. with 1 mm size tip.||1 No. with 1 mm size tip.||1 No. with 1 mm size tip.|
|Spraying Nozzle for Bottom Spray||1 No. with 1 mm size tip.||1 No. with 1 mm size tip.||1 No. with 1 mm size tip.||1 No. with 1 mm size tip.|
|Peristaltic Pump||0.25 hp with 4 to 100 ml / min||0.25 hp with 4 to 100 ml / min||0.25 hp with 4 to 100 ml / min||0.25 hp with 4 to 100 ml / min|
|Inlet Air Filter||20 micron||20 micron||20 micron final||20 micron final|
|Machine Dimensions in MM||450 x 600 x 1050 mm||450 x 600 x 1050 mm||950 L x 1150 B x 2630 H||1900 L x 1050 B x 2700 H|
|Case Size in MM||600 x 700 x 1100||600x700x1100||55" x 45" x 86"||1st Box- 2080 x 1500 x 2300
2nd Box – 1170 x 1170 x 700
|Net weight||160 Kg||160 kg.||350 Kg||400 Kg|
|Gross weight||290 Kg||290 Kg||500 Kg||550 Kg|
Supporting Utility Required
|1||Electrical Supply 3 Ph Model||3 Phase 4 Wire with Switch plug unit near to Equipment|
|2||Air pressure [If Pneumatics fitted Model]||6 bar|