Manufacturing - Granulation

Granulation - Fluid Bed
Our large capacity fluid bed dryers are used to produce a wide range of granulated materials. Liquids are introduced into the chamber with a spray system while the product is being moved by heated air to create the granulation. When the product has been dried to the required moisture level it is milled and screened to collect the desired mesh size. What are fluid bed dryers? Fluid bed dryers are designed to dry powder particles, where the residual moisture content is higher than what is wanted in the final powder. Hot drying air is distributed through specially designed perforated plates, on which the powder particles/agglomerates are resting.

The velocity of the drying air makes the powder ‘fluidize’, i.e. the particles get airborne; however, to the extent that only the finest/smallest particles leave the fluid bed with the air, while the bigger particles/agglomerates are conveyed/transported with the upward and forward directed flow of air (due to the perforation technique of the plate) into the subsequent section. Here cold and/or dehumidified air is introduced to cool the powder to the wanted temperature. Fluid bed drying is suited for powders, granules, agglomerates and pellets with an average particle size between 50 microns and 5 mm.

Granulation - Fluid Chilsonation
Hi-Tech offers Chilsonation systems that are used to create granulated products when no liquid can be added to the raw material. Raw material is passed between high-pressure rollers to form a sheet of material that is processed through a Fitzpatrick Mill that grinds the product into a granular form. The ground material is then screened to collect the desired mesh size.

Dry Granulation Capabilities
Hi-Tech Nutraceuticals has 2 processing rooms for dry granulation, both of which are dedicated to food and nutritional products. Each independent room has its own air, water, ventilation, and dust collection system to reduce the possibilities of cross contamination. Hi-Tech has one Fitzpatrick L-89 Chilsonator and one L-83 Chilsonator. All equipment has stainless steel contact parts. We have extensive experience dry granulating various sports supplements, weight loss ingredients, antioxidants, specialty chemicals, herbal extracts, calcium/magnesium carbonate, and hydroscopic or low-melting point ingredients.

Why Dry Granulation?

To create a desired particle size. Through dry granulation, you can take a powder, increase the particle size, and control the distribution of the particle size.

For blending similar products. Often times, our customers need to blend different materials that vary in particle size. By matching particle sizes, they can achieve a uniform blend.

To improve product flow. Powders tend to tunnel and cake. A granular product allows your product to flow freely through your production process.

To increase/decrease bulk density. By controlling the bulk density, you can control the flow and metering ability of a product.

To control particle hardness. Particle hardness can affect the dissolution and dispersion rates of a product. Also, the hardness of a particle helps to limit the disintegration of the product. By varying the pressure of the rolls in the chilsonator, we can improve the performance of a product.

To reduce dust. A dusty work environment is not only a nuisance but can pose a serious health and explosion risk. A granular product significantly reduces dusting.

Cost. Dry granulation is a much cheaper process than wet granulation.