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Three birds with one stone

Spouted bed technology allows spray granulation, agglomeration and coating of difficult-to-fluidise products
Three birds with one stone

Three birds with one stone
From laboratory to production: the spouted bed technology is available in various sizes
The German-based company Glatt has developed the patented spouted bed technology for spray granulation, agglomeration and coating of difficult-to-fluidise products. From the laboratory and pilot scales, this technology is now entering the production floors of the food processing, chemical and pharmaceutical industries.

Sebastian Pfütze

The Glatt Group has developed and supplied batch and continuous fluid bed equipment and systems for spray granulation, powder agglomeration, encapsulation, drying and coating of particles for several decades. At Powtech 2005, the company had its first ProCell 5 lab-scale spray granulation and coating system on display. It employs a proprietary and patented spouted bed technology. The second scale-up step was demonstrated with the ProCell 20 pilot system at Achema 2006. In March 2007, the first full-scale industrial system, a ProCell 125 for the production of food aromas went on stream.
Substances that are difficult to fluidise are handled safely with the spouted bed technology. Examples of this category include extremely fine materials, products with a very wide grain size spectrum and products with an irregular surface structure or high stickiness. As a technological complement, this method extends the application of conventional fluid bed treatment and provides additional options for customised applications. Spray granulation, in particular, offers a number of advantages if very small particles with a homogeneous structure and uniform surface structure are needed.
Coating processes involving very high volumes can also be handled because both small and substantially larger particles can be fluidised in one unit better than in conventional fluid bed equipment. The layout of the process air distribution system and the processing chamber is typical of this process technology. Several technical advantages, which include a patented air inflow design and no bottom screen, allow clog-free operation and new solutions in process control. The process air enters via a longitudinal slot which has process control.
The air repeatedly moves the particles in a defined direction through the nozzle spray zones, allowing optimum process conditions such as injection of liquid raw materials, standard granulation and particle coating processes. The expansion of the process chamber causes a sudden drop in the process gas velocity and facilitates the production of very small particles. On the other hand, large products like catalyst rings can be processed without requiring uneconomical air flows. The high gas velocity in the slot makes the process robust, especially with sticky products. Lumps are moved and disintegrate or are discharged.
Compared to fluid bed processes, much less product is needed to form the bed material in the processing chamber, since the product is concentrated in the spraying zone. This is a positive factor, especially for thermally sensitive substances, which are processed and discharged more rapidly. As a result, higher active levels are achieved compared to standard process options. Particles are fluidised without a sieve and a controlled flow of product is directed to the nozzle. This enables working at low bed temperatures and dramatically reduces the stress to which temperature-sensitive substances are exposed. Reference products include microorganisms, enzymes, nutritional oils, and other proteins and emulsions of flavouring substances. Traditionally, these products are dried in the spray drier, then granulated and coated. Direct spray granulation of such liquids is not possible with conventional fluid bed equipment because the longer residence time causes higher loss of activity than the spray drier.
Continuous or batch production
The ProCell 5 laboratory system is capable of both batch and continuous operation. In continuous mode, the zigzag classifier provides delivery. The discharged product is sifted and undersize particles are returned to the process. Alternatively, batch mode is possible simply by closing the discharge. Operation is supported by the spouted bed and fluid bed processes. In the standard version, the filters are arranged directly above the process chamber (internal filter). Optionally, dust in the exhaust air can be separated in a cyclone and/or filter in the machine cabinet base (referenced as external filter).
The new method is ideal for all applications for which conventional fluid med machines are available from Glatt. This includes design versions for the food processing, chemical and pharmaceutical industries as well as peripheral units, for instance for process air treatment or dust separation, use in potentially explosive atmosphere, WIP/CIP systems, provision of input materials and product handling.
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