Laboratory spray granulator

The laboratory spray granulator is not a simple "dryer", but a powerful "particle process development platform". Its main function is to simulate and optimize industrial production processes at a laboratory scale with minimal material consumption, providing crucial data and sample basis for creating granular products with ideal properties such as particle size, flowability, solubility, and coating effect.

From the perspective of structure, the laboratory spray granulator usually includes the following key components:

Small fluidized bed chamber: a transparent container made of glass or stainless steel, used to hold powder base material and observe the fluidized state of particles.

Spray system: a precise nozzle (usually air flow or pressure type) used to atomize liquid (such as adhesive and solution) into small droplets.

Air supply system: Provides filtered and heated air for material fluidization, drying, and evaporation.

Control system: precision computer or touch screen controller, used to accurately set and record all key parameters such as air volume, air temperature, material temperature, spray pressure, spray rate, etc.

Capture device: such as bag filter, used to collect fine powder generated during the experimental process.

The laboratory spray granulator is widely used, and its core value lies in providing data support and sample preparation for product development and process amplification. Specific functions include:

1. Process development and optimization (core use)

Formula screening: Researchers can test different formulas in small batches (tens of grams to several kilograms) to see which one can form the best particles.

"Parameter exploration": through precise control and adjustment of wind speed, temperature, spray rate and other parameters, find the best process conditions for producing ideal particles. This can greatly reduce the high cost and risk of trial and error directly on large-scale production equipment.

2. Particle engineering design (creating particles with specific properties)

This is one of its great abilities. By adjusting the process, particles with specific properties can be actively "designed":

Improving flowability: Manufacturing spherical, smooth surface, and uniformly sized particles to enhance their flowability, facilitating subsequent compression, capsule filling, or packaging.

Control particle density: It can produce lightweight porous particles (instant) or dense particles.

Achieving target particle size: precisely control the size and distribution of final particles by controlling spray and fluidization conditions.

3. Implement multiple technological processes

A device can complete multiple tasks by setting different parameters and operating modes:

Spray granulation: spray the solution or suspension on the powder particles, and make the particles adhere to each other and grow up through the liquid bridge action to produce larger and more uniform particles.

Bottom spray coating: By using a special bottom spray device (such as Wurster orifice plate), particles (such as pills, microspheres) can be coated with a very uniform thin film for taste masking, moisture resistance, controlled release, etc.

Top spray drying: similar to small spray drying, the solution is directly dried into powder or particles.

4. Prepare small batches of high-quality samples

Prepare limited but high-quality samples for clinical trials, consumer testing, stability studies, etc.

Prepare particle materials with special properties for academic research.

Main application areas

Pharmaceutical industry (largest user)

Drug formulation development: preparation of granules for tablet compression.

Slow release formulation: Prepare controlled release microspheres through coating technology.

Taste masking: coating bitter drugs.

Food and dairy industry

Develop instant milk powder, protein powder, fruit and vegetable powder, etc.

Study the granulation and solubility of food formulas.

Chemical Industry and New Materials

Develop catalysts, dyes, ceramic powders, polymer materials, etc.

Wrap and pelletize fine chemical products.

research institute

Conduct basic research on particle science, powder mechanics, drying kinetics, and other related fields.

Components of laboratory spray granulator

The system configuration consists of components such as drying chamber, atomizer, electric heater, filter (multi-stage), air supply fan, feed liquid pump, cyclone separator, material receiving bucket, operation ladder, etc

Laboratory spray granulatorProcess requirements

Water evaporation rate ≥ 60 kg/h

Drying room size with a diameter of no less than 2500 mm

The speed of the atomization device can be adjusted by frequency conversion, with a maximum speed of ≥ 10000 rpm

Product recycling method: tower bottom+cyclone separator 2-point recycling