Fluid Bed Dryer -Fluid Bed Dryers, Fluid Bed Processors

Fluid-bed Dryer is single purpose fluid-bed system used for drying solid materials. The system includes AHU, material bowl and processing chambers, exhaust air filtering units and control parts. Filtered hot air blows up materials to fluidized state, taking away moisture from materials and exhaust to external environment through filters.

Fluid bed Coater – Fluid Bed Processors

FBD Fluid-bed Dryer is one of the most common machines used in pharmaceutical production for drying. It is also widely used in food, chemical industries.

1. Inlet Temperature

Impact:

• Drying Efficiency: Higher temperatures accelerate drying but can also lead to uneven drying or thermal degradation of the material.
• Static Charges: Excessive heat can increase static charges, which can cause agglomeration or poor fluidization.

Optimization Tips:

• Controlled Heating: Use a controlled heating system to maintain a consistent and optimal temperature.
• Temperature Profiling: Regularly monitor and profile the temperature to avoid hotspots and ensure uniform drying.
• Balance: Aim for a balance between drying speed and product quality to avoid excessive heat that could cause degradation.

2. Atomization

Impact:

• Droplet Size: The atomization air pressure affects the droplet size of the coating solution. Smaller droplets lead to finer coatings but require higher pressure.

Optimization Tips:

• Adjust Pressure: Optimize atomization air pressure to achieve the desired droplet size and coating uniformity.
• Nozzle Selection: Use nozzles designed for the specific coating solution and desired droplet size.
• Consistency: Ensure that the atomization system is regularly maintained to avoid inconsistent droplet sizes.

3. Blower Speed

Impact:

• Fluidization Quality: Higher blower speeds increase fluidization but can cause excessive attrition and fines.
• Uniformity: Proper airflow is crucial for achieving uniform coating and drying.

Optimization Tips:

• Flow Adjustment: Adjust blower speed to maintain stable fluidization without causing excessive attrition.
• Monitoring: Continuously monitor the bed’s behavior to ensure that the airflow is optimal for the process.
• Uniform Distribution: Ensure the air distribution plate is well-maintained to avoid uneven airflow.

4. Partition Column or Air Distribution Plate

Impact:

• Fluidization: The design and height of the partition column affect the fluidization and coating efficiency.

Optimization Tips:

• Design Consideration: Choose a partition height that matches the particle size and density for optimal fluidization.
• Regular Checks: Inspect and clean the air distribution plate regularly to ensure even airflow and proper fluidization.

5. Spray Rate/Pump

Impact:

• Coating Uniformity: Spray rate affects the droplet size and coating uniformity.

Optimization Tips:

• Consistent Pumping: Use a peristaltic pump for consistent spray rate and avoid fluctuations.
• Rate Adjustment: Adjust the spray rate according to the drying capacity of the equipment and the desired coating thickness.

6. Relative Humidity

Impact:

• Agglomeration: High humidity can cause lump formation, while low humidity can increase static charges.

Optimization Tips:

• Controlled Environment: Maintain relative humidity within a controlled range to prevent sticking and static issues.
• Dehumidifiers: Use dehumidifiers if necessary to manage the humidity levels effectively.

7. Strength of Coating Solution

Impact:

• Nozzle Blockage: Higher viscosity solutions can lead to nozzle blockage.

Optimization Tips:

• Solution Consistency: Adjust the concentration of the coating solution to balance between viscosity and coating effectiveness.
• Maintenance: Regularly clean nozzles and equipment to prevent blockages and ensure consistent spraying.

A fluidized bed dryer is an industrial dryer used to dry granular materials, powders, or particles. It operates by suspending solid particles in a bed with upward flowing air or gas, causing the particles to behave like a fluid. Heat is applied to the fluidizing medium, drying the particles as moisture evaporates. Fluidized bed dryers offer advantages such as uniform drying, gentle handling of materials, short drying time, and energy efficiency. They find applications in various industries requiring efficient drying processes.

Salient Features:

• Very versatile process equipment.
• Fully automatic operation based on PLC ocontrol. (optional)
• Minimum handling and more hygienic.
• Top Mounted telescopic cylinder for auto bag shaking. (optional)
• Clamp type bottom mesh for container.
• Capacity available from 2.5 kgs. to 300 kgs.
• MOC SS 304/316/316L
• cGMP with documentation.

Fluid Bed Processor – fluid bed processors, what is fluid bed processor, dew point in fluid bed processor

Salient Features of Fluid Bed Processors

• In compliance with cGMP procedures/ regulations
• A Single pot technology for mixing, granulating & drying
• Shorter cycle time resulting in increased productivity
• PLC controls ensure high degree of process of control parameters ensuring batch-to-batch reproducibility
• In FBP, the powder particles are fluidized and then granulated by effective top spraying mechanism of binder
• The FBP ensures reduction in manpower, utility, space etc. Hence there are benefits like less utility consumption, less material handling, reduction in dust level, reduction in product exposure to the environment and operator’s exposure to the product.
• Most hygienic and minimum cross contamination problem.
• Broken bag detector ensures no product loss.
• Basic machine with SS 316 product contact parts & other non-contact parts made of SS 304
• AHU with electric heaters or steam coil with counter flange. Standard AHU is MS powder coated sheet.
• Pneumatic bag shaking. A filter bag is used to retain the fines
• Pneumatic operated inlet damper ON/OFF
• Pneumatic operated outlet damper 0% to 100% through I/P
• PLC based operations with 7″ color HMI (10” or 12” optional)
• All Inflatable Seals are transparent silicon. Peristaltic pump with trolley
• Spray nozzle, all electricals & pneumatics are of reputed brand & solid flow monitor (Broken bag detector)
• The bottom chamber is uniformly mixed with hot air before allowing it to enter the product container. The container and bottom chamber have suitable flange to fit inflatable silicon seal to achieve leak-proof operation (MOC SS 304)
• The product container has perforated plate in which there are several holes of equal diameter for uniform distribution of air through the product. The bottom sieve is with Dutch weave sieve acts as product retaining filter.
• The product container is facilitated with Product bed sensor, sight glass, sampling device. It is mounted on the SS 304 trolley having PU wheel (lockable) for easy & gentle movement
• The spray and retarding chamber consist of an expansion zone where spray nozzle is fitted and upper portion of the filter housing where filter bag assembly is placed. Multiple Spray ports provided for vertical adjustment of nozzle. Two view glasses provided with light source for observation of spray jet and filter-locking device. Main chamber & product container having flange to fit Inflatable seal to achieve leak proof operation. Explosion duct provided which works as a safety valve for the unit. When pressure increases above 2 bars; the disc opens, and pressure is released to atmosphere. Also, a limit switch will be activated upon opening of explosion disc which shuts down the machine operation
• The top & bottom filter ring holds the top & bottom end of the filter bag
• A filter bag shaking cylinder is to shake the filter bag at predetermined intervals to bring back the fines into product container which are deposited in the bag during the process. Shaker pneumatic assembly holds the bag assembly
• The spray pump with trolley is used to convey the binder solution from tank to the spray nozzle. spray pumps speed adjustment can be done through operating panel or on the spray pump. It is mounted on the separate SS 304 trolley
• The spray nozzle is used to spray the binder solution into the fluidized bed. For the vertical adjustments of the nozzle, multiple height mountings at spray port are provided in the retarding chamber. (MOC SS 316)
• The inlet damper is located on the bottom chamber flange and prevents water from entering the inlet duct during washing and prevents suction of air from inlet air handler during suction charging. ON / OFF Type (MOC SS 304)
• The outlet damper controls airflow depending on product & process requirement with the help of proportionate valve. (MOC SS 304)
• The airflow through the machine is produced by the blower by creating suction. It is located at the outlet end. The selection of the blower depends on the airflow requirement
• The inlet & outlet temperature measurement of the air can be set/display through PLC/HMI
• All pneumatic components are mounted inside the S.S.304 panel and fitted on support column of the machine

Providing an advanced fluid bed processing solutions for the years in the market. It offers a wide range of fluid bed dryers to meet the various industrial requirements at feasible price range.

• Pharmaceutical lab-scale (10L)
• Fluid Bed Drying production model (1000L)
• Fluid bed dryer FBD10
• FBD25 fluidized bed drying system
• FBD50 fluid bed dryer
• FBD100 fbd dryer
• FBD200 fluid bed dryer
• FBD300 fluidized bed dryer
• FBD 400 fluid bed drying system
• FBD500 fbd dryer
• FBD600 fluid bed dryer
• FBD800 fluid bed dryer
• FBD1000 fluidized bed dryers

Fluid Bed Dryer and Fluid Bed Processor are widely used in industries such as pharmaceuticals, food processing, chemical manufacturing, and spices for drying, granulation, coating, and other processes. Below is a breakdown of what these terms mean and their applications, along with related keywords and tags.

Fluid Bed Dryer

What is a Fluid Bed Dryer?

A Fluid Bed Dryer (FBD) is a piece of equipment used for drying granular or powdered materials. In this system, hot air is passed through the material in such a way that the particles are suspended (fluidized) in the airflow, enabling efficient heat and mass transfer.

Applications:

• Pharmaceuticals: Drying active pharmaceutical ingredients (APIs), granules, and excipients.
• Food Processing: Drying spices, grains, tea leaves, milk powder, and other food ingredients.
• Chemical Industry: Drying fine powders, chemicals, and fertilizers.
• Spices: Drying spice powders while maintaining flavor and aroma.

Working Principle:

• Airflow: Hot air is forced through a bed of material, causing the particles to become suspended in the air (fluidized state).
• Heat Transfer: The particles come into contact with hot air, which causes moisture in the particles to evaporate.
• Continuous Process: As the material is fluidized, it is continuously moved and dried in a uniform manner, ensuring consistency.

Advantages:

• Uniform Drying: The fluidization process allows for even drying of particles.
• High Efficiency: Faster drying rates and better energy efficiency.
• Gentle Drying: Reduced thermal degradation of heat-sensitive materials.
• Scalable: Suitable for small-scale or large-scale production runs.

Fluid Bed Processor

What is a Fluid Bed Processor?

A Fluid Bed Processor is a broader term encompassing various processes that use a fluidized bed to treat materials. While a Fluid Bed Dryer focuses mainly on drying, a Fluid Bed Processor can perform several processes, such as:

• Granulation
• Coating
• Drying
• Mixing
• Pelletization

This makes Fluid Bed Processors highly versatile for the pharmaceutical and food processing industries.

Applications:

• Pharmaceuticals: Granulating drugs, coating tablets, drying granules, and mixing ingredients.
• Food: Coating food products, drying powders, or creating granules for tablets or capsules.
• Cosmetics and Chemicals: Coating, drying, or mixing powders for formulation.
• Spices: Coating or drying spice particles, often used to improve texture or shelf life.

Processes:

• Granulation: Using binder liquids to create granules of powdery materials, often in the pharmaceutical and food industries.
• Coating: Applying a coating material (like sugar, polymers, or gelatin) onto particles, commonly for tablets or capsules in pharma.
• Drying: The material can be dried to remove moisture, just like in Fluid Bed Drying.
• Mixing: Uniform mixing of different powders or granules in a fluidized state to create homogeneous blends.