Fluid Bed Processing
For maximum production flexibility, GEA can supply a single fluid bed unit or the FlexStream fluid bed processor that combines multiple processes in a single piece of equipment.
GEA offers a series of fluid bed processors that are suitable for the formulation, development and production of clinical material through to full-scale manufacture; the philosophy behind the design is that a combination of standardised modules can be combined to meet specific requirements. As such, dryers of equal capacity may be completely different with respect to design, configuration and physical size.
Dryer: warm air is blown through a perforated distributor to rapidly and gently dry materials until the required residual moisture content is reached. Moisture evaporated from the product is exhausted with the drying air, providing very short processing times.
Precision Granulator: a novel granulation process, 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 the 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 1000) through the tube, allowing very large agglomerates to be built up.
Top Spray Granulator: offering granulation and drying in a single-pot process, the top spray granulator agglomerates finer particles into larger, free flowing granulates. 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 liquid, and instantizing.
Spray Dryer Granulator: with batch or continuous discharge available in continuous mode, 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. The product is discharged at a controlled rate to maintain an optimum bed height. Special features include easy scale-up and a small footprint.
PRECISION-COATER: this multi-functional fluid bed processor can be used to make pellets by layering the active material onto an inert core. Offering high spray rates for short processes, non-pareil starter pellets are sprayed with a solution or suspension of the active material and dried simultaneously.