Dry granulators are used for dry granulation process. The dry granulation process is used to form granules without using a liquid solution because the product to be granulated may be sensitive to moisture and heat. Forming granules without moisture requires compacting and densifying the powders. In this process, the primary powder particles are aggregated under high pressure.
Benefits of Dry Granulator
Energy efficient
The dry granulator uses high-speed rotating mechanical friction to crush, grind, and compact the materials, which has the advantages of high efficiency and energy saving. Compared with the traditional wet granulator, the dry granulator does not need to use a lot of water, avoids the energy consumption of drying and cooling, has high production efficiency and good results.
Easy to operate
The dry granulator adopts a fully automatic control system, which is very easy to operate and does not require professional skills to operate, reducing human errors during the operation. At the same time, there is almost no dust during the operation of the dry granulator, which is environmentally friendly and hygienic.
Constant pressure
The pressure of the dry granulator is a key factor affecting the granulation effect. The dry granulator has a more stable granulating effect, and the density and compressibility of the granules have higher consistency and reproducibility.
Low temperature granulation
Dry granulator is pressed into granules under higher pressure. During continuous granulation process, more heat is generated, and the temperature of equipment and materials will rise. The dry granulator has a cooling system that can take away the heat generated during the pressing process to ensure the stability of the main medicine during continuous production.
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Organic Fertilizer Granulation Machine
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The Difference Between Wet Granulator and Dry Granulator
Dry granulator traditionally refers to the extruded granulation technique, as there is no need to add water or adhesives to the compound fertilizer manufacturing process. In extruded granulation, the raw material is aggregated at high pressure in a fertilizer granulator as a primary powder, which is extruded between rollers to produce fertilizer particles. Granular fertilizers produced by wet granulator have a higher moisture content than those produced by dry granulation, so the finished product needs to be dried, cooled and cured. In the wet granulator process, the first 3 kinds of fertilizer granulators commonly used are drum granulator, disc granulator, spray granulator and tower spray granulator.
What are The Parameters of Dry Granulator?
Evaluation of various factors reveals that key process parameters in dry granulation include roller pressure, roller gap, and roller speed. Roller pressure significantly affects the properties of the granules, determining their hardness and density. Roller pressure that is too low can result in easily breakable granules and an excess of fine powder. Adjusting the roller pressure or increasing the feed rate can address issues with excessive fine powder.
What is The Particle Size Range Produced by a Dry Granulator?
Although granules used in the pharmaceutical industry have particle size in the range of 0.2-4.0 mm, they are primarily produced as an intermediary with a size range of 0.2-0.5 mm to be either packed as a dosage form or be mixed with other excipients before tablet compaction or capsule filling.
How Do you Optimize The Efficiency of a Dry Granulator?
The increased dry granulator volume can significantly improve the capacity of processing sieve particles, improve the speed of cutting, pressing, feeding three parts, but also effectively improve the overall production capacity of dry granulator. The capacity of the two-channel granulation box to pass through the screen is accelerated, which also reduces the material stored in the granulation box to be screened, effectively avoids the secondary cutting of the material particles to be screened, and improves the grain yield of dry granulator.
Material of Dry Granulator
The main materials of dry granulators include stainless steel, duplex stainless steel, etc., which are well used in pharmaceutical, chemical, and other industries. Stainless steel are chosen for their durability, corrosion resistance, and ability to withstand the mechanical stresses and abrasion associated with granulating various materials.
Can Dry Granulator Handle Heat-Sensitive Materials?
Unlike wet granulation methods, which involve the use of water or solvents, dry granulation relies on mechanical compression to form granules without exposing the material to high temperatures. This makes dry granulation suitable for processing heat-sensitive substances such as pharmaceuticals, food ingredients and certain chemicals. By avoiding heat during the granulation process, dry granulators maintain the integrity of sensitive materials and prevent their properties from degrading or changing.
Application of Dry Granulator
The pharmaceutical industry
Within the pharmaceutical industry, the dry granulation process is primarily used to increase material flowability and prevent particle segregation, facilitating faster and more consistent feeding into the tableting process.
The chemical industry
Similar to the pharmaceutical industry, the chemical industry often requires the physical properties of a powder to be improved. As such, employing dry compaction techniques and technologies can greatly facilitate their production. Typical applications are seen in battery mass production, fine chemicals, fertilizer and other agricultural products.
The food & beverage industry
The food and beverage industry relies on dry granulation for the production of tablets and pills (e.g., vitamins and supplements), as well as flavor extracts, instant blends, and other powder-based products.
For some antibiotic granules or dry suspensions, dry granulation is basically the first choice. Especially suitable for water-sensitive ingredients and heat-sensitive ingredients and materials.
The dry granulator is composed of a feeding mechanism, a tablet pressing mechanism, a hydraulic mechanism, a frame, and electrical control components. A feeding system, which conveys the powder to the compaction area between the rollers. A compaction unit, where the powder is compacted between two counter rotating rolls by applying a force, to form ribbons or flakes. A size reduction unit, for milling the ribbons into granules of the desired particle size.
Maintenance Tips for Dry Granulator
Regular clean
Before using the dry granulator, thoroughly clean the dust and impurities inside and outside the equipment, especially the drum, feed hopper and other important parts of the equipment. During use, dust and impurities inside the equipment should be cleaned regularly to avoid damage to the equipment. It is strictly forbidden to use acids, alkalis and other corrosive cleaning agents.
Lubrication
Important components such as rollers and bearings of dry granulators need to be lubricated regularly to maintain good lubrication and reduce friction losses. During use, it is necessary to check the normal operation of the lubrication system in time to ensure the lubrication effect.
Regular Maintenance
During use, the dry granulator may have some malfunctions, such as looseness, breakage, wear, etc. At this time, it must be dealt with in a timely manner to avoid affecting the normal operation of the equipment. When a fault is discovered, the power must be cut off and the machine shut down in time to find out the cause of the fault and carry out repairs.
Regular inspection
Regularly check the fasteners in various parts, including the transmission system, feeding system, hopper, etc., to ensure that they are in a strong and reliable condition. Check the sealing of the inlet, outlet and neutron device to ensure there is no leakage.
Things to Note When Using Dry Granulator
Before using the dry granulator, sufficient inspection and adjustment should be carried out to ensure that all parts are normal. When operating the dry granulator, you should operate it in accordance with the instructions and do not overload or overload it. When maintaining the dry granulator, you should follow the instructions and do not disassemble or modify it yourself. Before repairing the dry granulator, the power supply should be cut off or safety isolation should be carried out to avoid safety accidents. Check whether the electrical system, control system and other instruments are operating normally. If any abnormalities occur, they should be dealt with promptly.
Working Principle of Dry Granulator
In the dry granulator process, the powder is horizontally conveyed by a screw feeder, subjected to degassing and pre-compression under the action of a vertical screw feeder, pushed into the arc-shaped groove between two squeezing rollers, and transformed into flakes by the pressure exerted by the rollers. After passing through the rollers, the flakes, under the influence of gravity and surface tension, detach from the rollers. A small amount of unseparated flakes is scraped off by a scraper, and all detached flakes continue into the crushing and granulation machine, where they are processed into granules through the crushing and granulation process.
What Safety Features are Typically Included in Dry Granulators?
Includes emergency stop buttons, interlocking systems and safety guards to prevent access to moving parts during operation. Some dry granulators are equipped with an overload protection mechanism to prevent damage caused by excessive pressure or external force. Safety sensors and alarms can also be installed to monitor key parameters such as temperature and vibration, alerting operators to potential hazards or abnormal conditions.
The Difference Between Wet Granulator and Dry Granulator Granulation
The principles are different
Dry granulation does not require the addition of a liquid phase, and the strength and stability of the particles are enhanced mainly through physical effects. The operation is simple, but the mass transfer is slow. It is suitable for granulation where the interaction between powder materials is large or there are restrictions on humidity, solvents, etc.; wet granulation French granulation requires liquid as a binder and utilizes the flow properties of liquid-solid mixing to form particles.
Different production processes
The dry granulation process is simple and the production cost is low; the wet granulation process is relatively complex, the device is large and the moisture content needs to be controlled during the working process, which is relatively energy-consuming.
Product effects are different
Dry granulation has a wide range of particle shape and size distribution, smooth particle surface and high solidity; however, the disadvantage is that there are many voids inside the particles, which is prone to dust generation and surface structure damage. The granules produced by wet granulation have better quality, high density and high molding rate, but the shape of the granules is difficult to maintain and clogging or adhesion is prone to occur.
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Jiangyin Baoil Machiney Manutacurngo. Ltd. has been established since 2004, relies on its strong funds, strong technical force and complete processing and testing equipment, the use of foreign advanced technology. Production of all kinds of itermational advanced level of crushing mixing equipment, products exported to North America, Europe, Asia.
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