FLUIDIZED BED DRYERS

Q-TECHNOLOGIES GROUP GMBH presents fluidized layer dryers of FB, FBG and FBGP series branded as QUARCO. This equipment is intended for granulating of substances and drying of the obtained granulate and for substance mixing in fluidized layer. Dryers of these series differ by functionality and purpose. FB series is intended for granulate drying, FBG series – for drying and granulation and FBGP series – for drying, granulation, granulate coating and preparing of pellets. The mentioned equipment is widely used in pharmaceutical and food industry as well as in production of dietary supplements and formula feeds.

Drying, granulation and coating processes are critically important in manufacture of solid therapeutic forms as to minimize losses of excipients and expensive active ingredients during processes. Fluidized bed drying is the most effective way to dry the solids. The liquid comes out from the surface of each granule. Fluidized bed drying has indisputable and evident benefits: excellent heat exchange is provided, ideal drying time is kept, product is treated softly and effectively that is especially important for temperature sensitive materials. Besides, the fluidized bed principle enables drying in delicate conditions, not affecting the granule structure and provides uniform drying of granulate bed.

Fluidized bed dryers QUARCO PHARM & MEDICAL EQUIPMENT of FB series conform to all the above requirements.

Principle of action of fluidized layer dryers (drying, granulation, coating, pelletizing):

Fluidized bed granulating is a modern method to make granules from powder or similar materials. Water and other organic solvents may serve as spraying liquid in this process. Produced granulate is subjected to drying and (if necessary) cooling. As the action of mechanical forces is relatively low in the fluidized bed granulation, this results in loose granulate of low bulk weight and excellent water solubility.

Product pan for upper spraying is used for drying and granulate production. Pan configuration provides uniform distribution of airflow promoting uniform lifting of dry components during granulation and of wet granulates during drying.

Technical characteristics of FB and FBG models:

QUARCO fluidized bed dryers of FBGP series combine the options of granulation, granulate drying, granulate coating and pelleting.

Modern coatings may qualitatively affect the final product characteristics due to use of protective films. Material uniformity is critically important in coating as the process should provide an absolutely even coating without mechanical defects or gaps. Film coated is technically demanding operation that may be used in the widest range.

Powder is mixed and moistured during pelletizing. Binding solvent may be added at the same time. Centrifugal movement inside camera produces agglomerates forming into united dense capsules. Several product characteristics may be improved or realized by direct or layered granulation.

Product pan with layer suspension spraying and Wurster is used in granulate and pellet coating.

Product pan with tangential suspension spraying is used for pelletizing.

Technical characteristics of FBGP model dryers::

Differences in functionality and purpose of QUARCO fliudized bed dryers:

All models of QUARCO fluidized bed dryers fully conform to international GMPrules

Features of QUARCO PHARM & MEDICAL EQUIPMENT fluidized bed dryers:

1. If wished by consumer, control system fully compliant to FDA 21 CFR part 11 requirements is mounted in all dryers set in a language determined by consumer. The mentioned standard aims at transparency of production process that is critically important for people’s life and health and is attained by record keeping about the equipment itself, raw materials used in manufacture, technologies and actions by service staff. The records greatly reduce the risk of wrong use of different pharmaceutical components, deviations from manufacturing technologies and detect faulty personnel actions providing back tracing of any pharmaceutical product batch. The presence of different access levels protected by paroles is also important as it enables to register any interference into the process control system in the protocol form.
2. Control system displays:

Mnemoscheme	Parameter calibration
Current state of drying effector mechanisms and real-time probe readings are displayed	This display calibrates probes according to the real value
Plots	Parameter control
Displays air and suspension temperature trends, process air consumption, pressure in the column and other parameters	Display sets minimal values for controlled parameters
Discrete input check	Discrete output check
Displays the state of discrete inputs	Displays the state of discrete outputs

3. Sampler in QUARCO dryers provides tamper-proof product sampling out of the dryer column. Sampler container has Tri-Camp fastener enabling to mount and remove it in a very short time period.



4. Separate placement of power and pneumatic main engine cabinets results in more convenient maintenance services.
5. Dryers are intended for pressure of either 0.2 or 1.0 MPa by the shock resistance may be produced. All models of QUARCO PHARM & MEDICAL EQUIPMENT dryers are equipped with devices from worldwide leading manufacturers.

Standard configuration and components of QUARCO PHARM & MEDICAL EQUIPMENT fluidized bed dryers:

1. Watson Marlow peristaltic pump is known for its simple design as it is free of valves or gaskets liable to littering or corrosion. Working medium contacts only with inner surface of silicone tube thus completely removing the risk of cross-contamination of the pump and medium. Peristaltic pumps may also work in a dry mode.



2. Vessel for substance preparing AISI316L is made of stainless steel. Pneumatic pump helps to decrease the equipment costs when organic coatings are used. Only explosion-proof components should be installed in such facilities. Preparing vessel may be made with electric heating, steam jacket, without heating or in other configuration as requested by customer.



3. Air supply module is equipped with three degrees of cleaning in a standard configuration: pre-filter G4, fine filter F8 and HEPA filter H13. Electric heating of inlet air is used in a standard set for laboratory and small series models. Steam heating is used in other cases. Heat exchanger type may be changed as requested by customer.
4. Exhaust module is equipped with pocket G4 filters and fine F8 filters in a standard configuration.

Optional configuration and components of QUARCO PHARM & MEDICAL EQUIPMENT fluidized bed dryers:

1. Schlick sprayer: Family of two-component Schlick sprayers of 937 series is very wide; they have 3-7 spraying nozzles enabling optimal selection of sprayer for the dryer performance.
2. Blagdon Pump diaphragm pump: These pumps are ideal to supply highly viscous suspensions. Diaphragm pumps have a simple construction and thus they are simple in maintenance. Energy of compressed air is used to drive the membranes. Blagdon Pump pumps are certified by FDA, GOST-R, EC ATEX, EHEDG.



3. CIP washing system: Use of CIP automatic washing system ensures the repeatability of the washing process and enables its validation. CIP washing system may be supplied both with and without the accumulation tanks as requested by customer. CIP system has evident advantages: absent human factor, stable washing quality, control of water, power and detergent consumption.
   
   



4. Air dryer: Use of air dryers provides the required product quality regardless of seasonal fluctuations in air humidity and improves machine performance, assuring repeatable results between series. Air drying enables to lower the drying temperature that is important for protein compounds.
   
   

 

5. Exhaust module may be additionally equipped with high-efficiency H13 filter. We mount the system of air purification made by Donaldson Company, Inc. if potent substances are intended to be made.