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Granulation Processing Service Abstract
Granulation services provided byensymm for pharma, food processingand chemical industries based onamongst others a fluidized bed dryer(FBD) approach
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WHAT IS GRANULATION?
Granulation is the act or process offorming or crystallizing into grains.Granulation processes include the useof extrusion, high shear mixing andfluidized beds. The equipment usedfor granulation also determines thetype of granulate generated in theprocess with respect to shape,chemical composition and structure.
Granulation is carried out for variousreasons:▪ Granules prevent segregation of
constituents▪ Granules have improved flow
properties▪ Granules emit less amount of dust
Several industries like the detergentindustry are using enzymes. Thoseproteins in heavy-duty detergentsdegrade, and thereby help solubilize
substrate soils attached to fabrics orhard surfaces (e.g., dishes).
The enzyme rich ultra filtrate can besprayed dried and introduced into thedetergent in powdered form. The dustin the environment has high proteaseconcentration and can causeallergenic reactions. Hence theproteases are an environment hazardin the powdered form and have to begranulated for a secure application.
To protect both detergent plantoperators and end users, the enzymeparticles have to be coated in such away that no active enzyme dust ispresent or released during handling.In all cases, one or several coatinglayers ensure that granulates have lowdusting properties.
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APPROAACHES OF GRANULATION
Fast-Mixer-Systems
With fast-rotating mixing systems of„ploughshare“ type or Schigi typemixers with horizontal or verticalshafts, equipped with blenders, thehigh turbulence in the rotatingmixture of ingredients determines theparticle size.
Prilling Process
The total mixture of ingredients istransferred into a molten mass of lowviscosity in which insolubleingredients have to behomogeneously distributed. The meltis pumped through insulated tubes ofthe top of a tower where it is sprayedby nozzles or a rotating disk. The finalsteps are cooling in continuous fluidbeds and sieving of the solidifiedprills.
Extrusion Process
After mixing the dry ingredients, thedry premixture and the liquid enzymeconcentrate are fed batchwise in amixing system to obtain a moistdough-like mixture. This mass is fedinto a twin-screw screen type extruderand pressed through thin perforatedmetal sheets with holes that are thediameter of desired particle size. Theextruded “noodles” fall by batchwisefeeding into a spheronizer. Thismachine, equipped with a fast-rotating disk, breaks the noodlesdown to cylindrical particles.
Solid corePVA-Layer
Enzyme Layer + PVA(NH₄)₂SO₄ layer
Polymer + PigmentNeodol Coating
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APPROACHES OF GRANULATION CONT.
Spray Coating of Core Particles
Granulation by spray coating generallyrefers to producing a particle byfluidizing a core material in a heatedairstream to pass through an area ofatomized liquid. This approach is alsoknown as the fluidized bed dryerapproach.
Granulation process based on the FBD approach
The atomized liquid droplets, whichcontain dissolved or suspended solids,dorm a fil on the surface of the corematerial. The coated core material isthen transferred from the spray zoneinto a drying zone. The solvent in theliquid is dried, leaving the dissolved orsuspended solids as a film on the corematerial. This process is continueduntil the desired amount of film isformed.Finally, the coated particles, whichhave an onion-like structure, may bescreened to obtain the desired rangeof particles.
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APPLICATION OF GRANULATION
Granulation is used in many industrial sectors
▪ Chemical industriesGranulation of enzymes as detergents, surfactants and others
▪ Food industries: Granulation of sugar, fat or oil, granules for instant-drinks, animal feed and many more
▪ Pharma industries: Granulation and coating of active substances and for food supplements, e.g., minerals, vitamins, amino acids and others
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APPLICATION OF GRANULATION CONT.
Granulation is a well established andfar-reaching process for manyindustries. Although the processparameters have to be adapted to therespective application, nearlyeverything can be granulated.
Ensymm offers the granulationprocess adjusted to your industry. Wecan help you to granulate yourproduct with all services you need.
What ensymm can do for you
▪ Formulation for your specific granules
▪ Analytics concerning your product
▪ Technical support for handling and installation of your FBD
▪ FBD supplier at new acquisition
ensymm is a German based premier project consultingcompany for Life Sciences, serving biotech companies,pharmaceutical industry and food ingredientcompanies. We provide clients with a variety of businessand technology consulting services as well as withspecialized teams in various areas of our competence.
For further inquiries and quotes, please contact:
ensymm UG & Co.KGLife Science Center DusseldorfMerowingerplatz 140225 DusseldorfGermany
Tel: 0049 [email protected]
