High Shear Mixer Granulators
SaintyCo High Shear Mixer Granulators include OSG Series Oscillating Granulator, SMG 2-6 Lab High Shear Mixer, SMG Series High Shear Mixer Granulator, SMG-H Series Rapid Mixer Granulators and SMG-T Series High Shear Mixer Granulator.
They feature a varying rotational speed with full enclosed lubrication and driving system. SaintyCo High Shear Mixer Granulator come in varying designs for dynamic material processing needs.
High Shear Mixer Granulator: The Ultimate FAQ Guide
If you are planning to mix and granulate powders, high shear mixer granulators offer a perfect solution.
However, you must learn how to choose high quality and reliable high shear mixer granulator.
But first, here are important things you must know:
- What is High-shear Mixer Granulator?
- What are the Advantages of High Shear Mixing Equipment?
- What are the Disadvantages of High Shear Mixer Granulators?
- How does High Shear Mixer Granulator compare to Fluidized Bed Granulator?
- What is the difference between Horizontal High Shear Granulator and Vertical High Shear Granulator?
- How does Low Shear Mixer Granulator compare to High Shear Mixer Granulator?
- What are the main Parts of High Shear Mixer and Granulator Machine?
- How does High Shear Mixer Granulator Work?
- What is the difference between High-shear Mixer Granulator and Rapid Mixer Granulator?
- What should you Consider when Buying High Shear Mixer Granulator?
- Which Industries use High Shear Granulator?
- Which Factors Affect Granule Properties of High Shear Mixer Granulator?
- Which Materials can you Process with High Shear Mixer Granulator?
- How do you Classify High Shear Mixer Granulators?
- High Shear Mixer Granulators should conform to which Quality Standards?
- How safe is High Shear Mixer Granulator?
- How many Types of Granulation are there?
- Which Materials can you process with Low Shear Granulation?
- What are the Advantages of High Shear Mixer Granulation?
- What is the difference between Wet Granulation and Dry Granulation?
- Can you use High Shear Granulator for Wet Granulation? What are the Processes involved?
- What are the Pharmaceutical uses of High Shear Mixer Granulator?
- Which High Shear Mixer Granulator Features increase Efficiency of Granulation Process?
- Why invest in SaintyCo High Shear Mixer Granulator?
1. What is High-shear Mixer Granulator?
High Shear Granulator is a machine used during wet mixing, homogenizing, granulating and drying of powder in chemical, food and beverage, plastic, cosmetic, pharmaceutical, and general mixing industries.
The machine comprises of:
- Either a conical or cylindrical mixing drum,
- An impeller with 3 blades
- Primary chopper
- Supplementary chopper
- Discharge pot.
Rapid mixer granulators can be generally categorized into two classes, which are vertical axis and horizontal axis, and you can operate them either continuously or in batch.
The three-bladed impeller of the equipment intensely agitate the powder and generate high-density granules.
High shear mixer
High speed mixer granulators are commonly used in agrochemical, detergent, and pharmaceutical industries due to their capability to manage difficult feed formulations, comprising of fine cohesive powders and high viscosity binder fluids.
2. What are the Advantages of High Shear Mixing Equipment?
Some of the main benefits of high shear mixing and granulation machine are:
- Needs small quantity of binder solution for granulation process.
- Achieves granulation within a short time.
- Needs short drying times.
- Predictable granulation endpoint
- Higher densification and creating granules which are less friable.
- Generates reproducible less friable granules having a consistent particle size distribution.
- Reduces operators’ exposure to drug dust because of minimized generation of process dust.
3. What are the Disadvantages of High Shear Mixer Granulators?
Here are the main drawbacks of high speed mixer granulator:
- Leads to irregular distribution of binder liquid on moving powder bed in the course of high shear granulation process.
- Has a limited scope of operating conditions.
- Granules over-wetting may result in development of large-sized lumps.
- Has potential of chemically degrading thermolabile materials due to temperature increase.
- Can mechanically degrade fragile particles.
4. How does High Shear Mixer Granulator compare to Fluidized Bed Granulator?
High shear mixer granulator
Operation of high shear granulator takes place in a closed unit that entails various steps including blending, primary and secondary granulation and drying.
Primary granulation entails spraying of the powder bed with the binder solution, while the secondary granulation entails working on the wet product to develop and enlarge the granules.
Subsequently, the machine dries the granules under moderate temperature and low pressure.
On the other hand, fluidized bed granulator applies fluidized bed processing (an air suspension method) for product granulation and drying, particularly pharmaceuticals.
Fluid bed granulator
Fluid bed granulator executes the granulation utilizing fluid beds having spray nozzles.
The process of fluid bed granulation involves spraying the fluidized powder bed with binder solution to produce finer, free-flowing and uniform granules.
High shear mixer granulator forms more spherical and denser granules than fluidized bed granulator, which produces irregular granules.
Granules produced by high shear mixer exhibit better general flow properties than those from fluidized bed granulator.
In comparison to fluidized bed granulator, rapid mixer granulator is a simpler and easily cleanable machine, which complies with GMP requirements.
As a result, you will get granules that properly compacted with spherical shapes.
Normally, this process takes a short time.
At the same time, it reduces possibility of cross-contamination during the production process.
5. What is the difference between Horizontal High Shear Granulator and Vertical High Shear Granulator?
These types of high shear mixer granulator are mainly differentiated by the geometric orientation and positioning of the main impeller.
A vertical high shear granulator has a bladelike impeller with a shaft that oscillates in the vertical plane.
Normally, vertical high shear mixing and granulation machine us driven either from the top or bottom.
On the contrary, a horizontal high shear mixer granulator has an impeller shaft that oscillates in the horizontal plane.
6. How does Low Shear Mixer Granulator compare to High Shear Mixer Granulator?
Inside high shear mixer granulator
Fundamentally, the main difference between these two classes of rapid mixer granulator originates from the magnitude of the force exerted by each machine on materials for uniform mixing and successive granulation.
Low shear granulators apply the small proportion of mechanical to blend and granulate powder granules, with a good example being a fluidized bed granulator.
With a low shear granulator, you will require a relatively small magnitude of mechanical force.
Consequently, they will produce granules with less density.
In contrast, high shear granulators use the large magnitude of mechanical force.
At the same time, they add granulation solution during the process.
As a result of the high speed, they produce high desist granules and better flow characteristics.
When dealing with highly cohesive material, then a high shear mixer granulator is the best choice.
Since such materials have high amount of hydrophilic polymer, low shear mixers are not recommended.
7. What are the main Parts of High Shear Mixer and Granulator Machine?
Rapid mixer granulator is a unit of various building blocks.
The parts of high shear mixing and granulating machine are:
Granulation or Mixing Drum/Container/Bowl
This is a container made from stainless steel with a number of accessories such as:
iii. Mixing blades
iv. Granulation solution spraying nozzle, etc.
The design of granulation bowl enables it to segregate the mixing compartment from the surrounding environment.
With high shear mixer, you will not experience any pollution due to dust.
Based on the design and capacity, there are mixing drums of various shapes and sizes.
Nonetheless, conical-shaped mixing bowls are popular.
With the slanting sides, granules can blend easily and freely.
Moreover, they lack sharp edges or corners that may hide granules.
Most mixing drums of high shear mixer granulator have a round base.
Normally, this design facilitates powder movement during mixing and granulation of powder.
The main function of the impeller is to blend mix materials and apply granulation solution.
Based on its design, the speed of rotation of the impeller may span from 100rpm to 1,500 rpm.
Depending on the high shear mixer orientation, impeller can spin either vertically or horizontally.
Most, high shear granulators have impellers with three blades which are tangentially placed.
This ensures efficiency and reliability.
The chopper of rapid mixer granulator breaks down wet lumps thereby forming granules.
Remember, the rotating speed of the chopper can be between 1000 to 3000 rpm.
Normally, it will depend on the impeller speed.
In most cases, the choppers have blades which are U-shaped.
Their position will depend on the design of the high shear mixer granulator.
Also, you will find mixing bowls with chopper fixed on the wall.
Sealing High Shear Mixer Granulator
They feature Teflon seals, which provide reliable sealing, making it comply with the cGMP requirements.
Proper sealing will prevent possible contamination and leakage during the high shear mixer granulation process.
Motor Drive System
A rapid mixer granulator requires a drive mechanism to facilitate the rotation of the impeller and chopper.
The machine has a motor drive mechanism that modulates and controls the process of granulation.
Most high shear mixer granulators come with variable frequency drive system(VFD).
With the VFD system, you can accurately control the speed or both the impeller and chopper.
As a result, you will achieve better granulation results.
This is the part through which the final granules leave the granulation drum for packaging or further processing.
Depending on the design of the high shear mixer and granulator, you can remove granules into a receiving container or sizing mill.
The structure and design of high shear mixer granulators determine the material used to make its frame.
Often, most machines have frame made from stainless steel.
This frame holds the essential components such as;
- Granulation bowl
- Drive system
- Electrical control systems, among other components.
You should ensure that your high shear granulator has a frame that is strong enough to sustain all weights as well as the vibrations throughout the process of wet granulation.
This is an instrumental component of any high shear granulator.
You should go for a granulation machine that excellently delivers granulation solution.
The spraying nozzle of any high speed mixer granulator needs to atomize and supply an appropriate quantity of binding liquid.
The nozzle should spray the binding liquid on the material uniformly.
Here are the factor to consider while choosing the best spraying nozzle for high shear mixer granulator:
Granulation Solution Pump
Generally, you have two types of binder solution pumps to choose from. Y
ou can go for either mechanical or peristaltic pump.
On the other hand, you may as well go specific pumps that will handle specific material you will be handling.
Pressure Port of Granulation Solution
You should go for pressure port for a perfect and efficient dispersion of granulation liquid.
With this, it will release binder liquid at high pressure and quickly.
Furthermore, the location of the granulator spraying nozzle will depend on the design of the rapid mixer.
However, in most cases, you will find it just above the powder you will be granulating.
The configuration, control software and design of your high shear granulator will determine the design complexity and design of its control system.
The control panel can come in as a touchscreen Human-Machine Interface.
Depending on the uniqueness of its design, the control system can:
- Facilitate modification of several process variables
- Display system parameters like the temperature of the system, impeller speed, chopper speed, and various warnings among others.
Presently, most high shear granulators employ PLC control systems.
8. How does High Shear Mixer Granulator Work?
The wet granulation process utilizing high shear mixer granulator can be categorized into these 4 main steps:
Step 1: Filling of Material into the Mixing or Granulating Drum
Loading of the materials into the granulating bowl depends on the type of granulator you are using.
For manual rapid mixer granulator, you will have to load the materials manually.
In other words, open the cover of the mixing drum, fill powder then shut.
In the case of an automatic high shear granulator, the machine fills the granulating bowl automatically with the material.
By simply pressing buttons on the system, the powder will flow into the drum automatically.
It is a fully automated process where it only stops after reaching the required level.
Step 2: Starting the Process of Mixing
The exhaust valve will open after successfully filling the material as the vacuum valves shut.
After this, both the chopper and the impeller will begin to rotate.
With the control panel, you can set the rotational speed of the high shear mixer impeller and chopper.
The design of this system is such that the chopper and impeller rotate in opposite directions.
Through this, you can easily get homogeneously blended powder.
Remember, the action of the chopper and impeller produces a rotational and tangential movement.
During this process, fluidization of granules occurs resulting in uniform mixing.
The process is such that, the powder will consistently move from the center of the granulation bowl to the margin.
Remember, during this process, the powder will not adhere to the stainless steel drum of the granulator.
Step 3: Addition of Granulation/Binder Solution
Adding binder solution
In this stage of high shear granulation, the system automatically turns ON the spraying nozzle, which will in turn spray the binder solution onto the granules that are in continuous random motion.
With the help of compressed air alongside the pump, binding liquid will precisely flow through the mixer granulator spraying nozzle.
At this step of granulation, the following processes happen concurrently:
- Rotation of impeller and chopper at set speed.
- Spraying of binder solution/granulation liquid.
- Granules under mechanical shear force moving randomly inside the granulation bowl.
At this point, the powder will start to agglomerate into granules.
Of course, the binder solution will make the granules wet hence producing large lumps.
It is the blade of the chopper that will reduce them to the required sizes.
Once you attain granules with suitable density and sizes, the high shear granulator can discharge the product.
Step 4: Discharging the Granules
The system will turn OFF the granulator spraying nozzle automatically.
Consequently, the speed of the impeller will begin to reduce.
Then, the high shear mixer will open the discharge opening.
It follows that, as the high shear mixer granulator speed will be reducing, the granules flow into the milling chamber.
The milling machine will then reduce the size of wet granules after which, you can take them to the drying chamber for next processes.
9. What is the difference between High-shear Mixer Granulator and Rapid Mixer Granulator?
There is no difference between the two names because they refer to the same machine.
Often, you will hear people referring to high shear mixer granulator as:
- Rapid mixer granulator
- High shear granulator
- High shear mixer.
You shouldn’t get confused since all these names stand for one machine.
10. What should you Consider when Buying High Shear Mixer Granulator?
When shopping for a high shear mixer, you need to be more vigilant on these three essential elements to optimize the process of granulation and save on your finite resources.
High shear mixer granulator design
i. Assess the Design of High Shear Granulator
You should evaluate the general design of the machine because it impacts on the efficiency of the whole process.
Assessing the design must entail all parts and components like but not limited to these:
- Granulating drum or bowl
- Design of impeller
- Design of chopper
- Spraying nozzle
- Drive mechanism
- Sealing mechanism
- Electrical and control panel
- Granules discharge
- Granules milling
- Machine frame and structure
Before buying a high shear granulator, you should ensure that the manufacturer explains why they have a particular design for a part or component.
More critically, ascertain whether such designs will boost the high shear granulation process.
When choosing a rapid mixer granulator, select a machine that has an ergonomic design capable of optimizing performance.
ii. New Technological Features offered by the High Shear Mixer
During your search for the right high shear granulation machine, you will realize that most manufacturers use the statements “feature our patented technology or new technology” in their product description.
However, they will barely state these technologies.
Therefore, you need to be very cautious with such sales stunts.
Yes, it is correct that technology will greatly enhance how a high shear mixer granulator work.
Therefore, whether you choose a horizontal high shear granulator or vertical high shear granulator, technology will still be instrumental in its overall performance.
Choosing a rapid mixer granulator with the right technology will ensure that you form granules with the correct size, shape, porosity and density.
Therefore, make sure your supply mentions the so called “new or patented technology” of their high shear mixer.
They should explain to you why they feel it is the best choice.
For that matter, let’s have a look at some of the technological innovations that will enhance the performance of a high shear granulation machine:
iii. Automation and Control Panel
These systems use microprocessors which enable them to control all the essential functioning of the high shear granulator.
High shear mixer granulator components
Here are some of the important aspects regulated by the control panel:
- Directing the drive system of the machine. These may include the speed of both the impeller and the chopper.
- Timing the duration of the granulation process; this consists of blending and spraying process.
- Ensuring safety of machine by Interlocking machine system
- Auto shutdown of equipment
- Monitoring pressure and temperature of the granulation machine.
- Automatic lubrication of system
- System diagnostic procedures, among other functionalities.
Most high shear granulators have control systems with LCD touchscreen HMI display.
This makes it possible for operators to monitor and control crucial parameters of the equipment via the panel.
iv. Process Data Accessibility
Keeping track of data through the HMI may not be adequate.
Some rapid shear granulators come with a USB port facilitating easy transfer of process data.
This allows for printing of the batch granulation data.
v. Vacuum Transfer System
Some high shear mixer granulators have vacuum transfer mechanism.
They apply it when filling and discharging material into and out of the machine.
This is an efficient and dependable transfer system.
In summary, always opt for a rapid mixer granulator that features advanced technology when you desire to optimize your wet granulation process.
vi. Assess the Technical Specification of the Machine
This information will help you establish the production capacity of the rapid mixer granulator.
You can find this information from the product catalogue or technical manual of the equipment.
It is advisable to select a machine with production capacity fairly greater than your present production requirements.
This will give you room for easy upgrade or expansion.
Common technical specifications of high shear mixer comprise of granulation specifications, impeller, chopper, motor, rotor and dimensions.
Therefore, always verify this information before you buy a granulation machine.
11. Which Industries use High Shear Granulator?
Rapid mixer granulator is a popular equipment that manufacturers employ to produce a variety of homogenous product mixtures.
Let’s explore some of the industries that commonly use high shear mixer:
High shear mixer granulator equipment
By applying high shear wet granulation technique, you can manufacture tablets and capsules with better:
- Flow characteristics
- Stable ingredients
Fertilizer Manufacturing Industry
Fertilizer manufacturers apply wet granulation machines to uniformly mix various chemicals and minerals constituents.
Moreover, they utilize high shear mixer granulators to generate dense granules having the right size and chemical composition.
Food and Beverage Processing Industry
Wet granulation is common technique applied in manufacturing a variety of chocolates, sweets, food concentrates, etc.
You can use high shear mixer to process/produce food products like instant coffee, milk powder, cubes, chocolate mix, among others.
Chemical Processing Industry
Producers in the chemical processing sector apply high shear granulator to blend different chemical ingredients to ensure, consistent, dependable and uniform products.
12. Which Factors Affect Granule Properties of High Shear Mixer Granulator?
Selecting the right high shear mixer granulator is not sufficient.
There are various variables that may affect the properties of the final products either directly or indirectly, and they include:
- Formulation variables; the amount and quantity of excipients used.
- The physical characteristics of the materials you need to granulate.
- The type and quantity of granulation solution utilized in the operation.
- Process variables which consist of;
i. Load of the granulating drum.
ii. Speed of the impeller
iii. Method of adding the Granulation/binder solution
iv. Rate of adding the granulation solution
v. Speed of the chopper
vi. Granulator design.
vii. Wet-massing tire
13. Which Materials can you Process with High Shear Mixer Granulator?
High shear mixer granulator components
You can use rapid mixer granulator to blend both wet and dry powders, which it can perform in a broad range of operating conditions such as function without changing pressure zones.
In addition, this type of granulation machine is a perfect option for highly cohesive material.
14. How do you Classify High Shear Mixer Granulators?
Usually, classification of high shear granulators depend on a number of factors.
When selecting these machines, you may choose the following options:
a) Type of Dosing System
Existing high shear granulators may have either manual or automatic systems.
The available granulation machines may have automatic and manual systems.
This may include powder and biding solution dosing system.
b) Impeller Blade Design
The design of the impeller blades of your equipment dictates the efficiency of the granulation process.
For this reason, a rapid mixer granulator may come with a varying number of blades.
For example, some machines may come fitted with a three-blade impeller.
Apart from design, the location of the impeller is equally important during the granulation operation.
Often, you will find most high shear granulators having impeller tips positioned tangentially because this eliminates the probability of dead spots.
Note that it is the impeller that will blend and spread the granulation solution.
Its speed of rotation will be dependent on the specification and design of the high shear granulation machine.
c) Orientation of the Impeller
In this category, you may either choose vertical or horizontal rapid mixer granulator.
This classification of high shear granulators relies on the location and geometric orientation of the impeller.
As we had earlier discussed in the guide, the impeller shaft of a horizontal high shear mixer granulator rotates in a horizontal plane.
This implies that they are side driven. Conversely, the impeller shaft of a vertical high shear mixer spins in a vertical plane.
This type of high shear granulation machine can be either top or bottom driven.
15. High Shear Mixer Granulators should conform to which Quality Standards?
By now, you realize that a high shear granulator is an assembly of pneumatic, mechanical and electrical and electronic systems.
For that matter, they should comply with the quality and safety standards in the market.
When buying a high shear mixer granulator, there needs to be proof that the machine complies with stringent manufacturing process.
Fundamentally, the cGMP is an essential compliance prerequisite for all high shear granulation machines.
The cGMP rules require that each equipment must have tight mechanical seals.
The high shear mixer needs to have better dust handling mechanism while guaranteeing high level of hygiene.
This clarifies why the whole structure of the machine is made using stainless steel.
In addition, the rapid mixer granulator should be manufactured from FDA certified materials with the electrical and electronic components being CE compliant.
Therefore, your high shear mixer granulator must be:
- cGMP compliant
- CE compliant
- ISO certified
- ASTM E2500
These are some of the many quality regulations a high shear mixer should comply with.
In some cases, the quality standards may differ from one region to another.
More crucially, you should purchase the equipment from a well-known manufacturer.
16. How safe is High Shear Mixer Granulator?
Lab high shear mixer
Safety is a critical feature of any electromechanical machine.
For this reason, high shear granulators come with several safety interlock systems.
For instance, it is not possible to access the drive system when the machine is running, and you cannot start the machine when the mixing drum is open.
In addition to the cGMP regulations, this equipment has an air pressure switch limit, overload relay protection, enclosed drive system and appropriate sealing mechanism.
17. How many Types of Granulation are there?
Granulation is the procedure of forming granules or grains out of solid or powdery material, manufacturing a granular material.
The process is applied in various technological operations in the pharmaceutical and chemical industries.
Normally, granulation process entails aggregation of tiny particles into larger granules, usually ranging in size between 0.2 and 4.0 mm based on their eventual application.
In rare cases, it entails grinding or shredding solid materials into finer pellets or granules.
There are three common types of granulation:
i. Wet Granulation
Wet granulation process
Wet granulation is the process of forming granules by adding granulating fluid onto a powder bed.
The powder bed is under the influence of screws (in the case of twin screw granulator), an impeller (in a high shear granulator or air (under fluidized bed granulator).
The granulating fluid is helpful in the massing of powder particles in the process.
However, the granulation fluid should be volatile and non-toxic.
It needs to be volatile since it is easy to remove by drying only a volatile fluid from the end product.
Also, the fluid should be non-toxic due to its intended application.
The commonly used liquids as granulating fluid consist of isopropanol, ethanol and water.
In some cases, you can use these solutions in combination.
When you use water in wet granulation, it is mixed with the powder creating bonds between the particles of powder.
However, water may not be the right granulating fluid if granules disintegrate during drying.
In such a scenario, you can use a bonder along with water.
In the traditional technique, the wet mass is pressed via a sieve to form granules which are subsequently dried.
When producing water-sensitive products, you can use an organic solvent as a substitute to water.
Inside we granulation machine
ii. Dry Granulation
Dry granulation is a procedure of forming granules in the absence of any liquid solution.
Dry granulation process
This type of granulation is the best choice when the ingredients you want to granulate are sensitive to heat or moisture.
Because the process involves no fluid, it needs compacting and densification of the fine material to transform it into granules.
In dry granulation, high pressure helps in the formation of the granules.
High pressure is applied to agglomerate the particles of the compound.
The commonly used equipment in dry granulation are slugging tool and roll compactor/table press machine.
However, note that when you use a tablet press for the process of dry granulation, the powders may not have sufficient natural flow to inject the product evenly into the die cavity.
This leads to differing degrees of densification, resulting in irregular granules when milled.
Let’s explore the two main methods of dry granulation:
The original technique of dry granulation applied a heavy duty tablet pressing machine to compact the dry powder.
The process of compacting process in this situation is referred to as “slugging’ and the compacted substance is in the form of “slugs”, usually 10-15 mm in thickness and 25 mm in diameter.
You can use a hammer mill to break up the slugs to form granules.
However, you can as well use a heavy duty rotary press or conventional tablet machine to compact the dry powder.
A gentler option to slugging is material compaction employing a roller compactor.
Commonly known as chilsonator, the device squeezes the mixed powder through two counter-rotating rollers to create a compressed sheet.
The formed sheets are fragile and snap easily into flakes, which require careful treatment to convert them into granules.
You can then mill the formed granules to the desired size.
· Direct Blending
This is a technique of mixing different wet components or powders with varying particle sizes and specific weight.
It forms a homogenous mixture of all the constituents for every manufacturing process.
The type of blender utilized will affect the flow properties of the resultant mixture, as will the sizes and shapes of particles of each of the raw materials.
The machines utilized to blend materials, for example, pharmaceutical powders are usually either rotating shell blenders (e.g. double cone, cross-flow, twin-shell, and drum) or fixed shell blenders (e.g. impeller mixers, screw or ribbon mixers).
Factors that influence the choice of blender include size, shape, density, and morphology of particles of the ingredients that you want to mix.
However, regardless of the type of blender used, there is possible stratification of the materials with large coarse pieces settling on the base of the blender.
The volume and flow rate of the material to be blended, the speed of the blender and the mixing time affects the ability to mix homogenously and not stratify.
All these variables will influence the end product thus you should be keen throughout the process of powder blending to maintain consistent blending parameters.
18. Which Materials can you process with Low Shear Granulation?
Low shear granulation is characterized by mixing the materials without reducing the size of the particles during the operation.
Low shear mixing is ideal for blending fragile or shear sensitive materials like adhesives, polymers, and structured food products.
Materials of this type tend to have a limit of shear rate beyond which they begin to change their features.
This behavior is normally called shear degradation.
19. What are the Advantages of High Shear Mixer Granulation?
You can process a variety of feed materials in high shear granulation than in other types and methods of granulation, including very viscous fluid binders and very fine cohesive powders.
This is because of the capability of the chopper or impeller of rapid mixer granulators to disintegrate lumps of materials and mechanically spread the binder solution.
In a nutshell, the three main advantages of high shear granulation are:
i. Can handle cohesive powders and disperse viscous binders.
ii. Will typically form a more robust product than other granulation processes.
iii. Only process to form tiny (less than 1mm) dense granules.
20. What is the difference between Wet Granulation and Dry Granulation?
In the wet granulation, you need to incorporate a granulation solution that can be either water or other solvents.
This solution is what assists in bonding the particles together.
In contrast, you do not require any kind of fluid in dry granulation.
The procedure primarily entails compacting powder particles in the absence of water or any solvent.
It is the force of compaction that is responsible for bonding the particles.
Additionally, dry granulation is appropriate for substances that are moisture and heat sensitive.
Materials of this nature are sensitive to both water and organic solvents.
Therefore, because of the differences in the types and methods of granulation, the design of the machines used in the processes are also different.
However, the complexity of both wet granulation and dry granulation processes will rely on the features of the material to be granulated.
21. Can you use High Shear Granulator for Wet Granulation? What are the Processes involved?
High shear mixer granulation machine
Of course, you can use high shear mixing granulation for wet granulation.
There are 5 main stages in high shear wet granulation process:
iv. Mixing of powder
v. Addition of binder or granulating fluid.
vi. Wetting of powder and nucleation
vii. Granules agglomeration and densification of the powder.
viii. Granule attrition and breakage.
22. What are the Pharmaceutical uses of High Shear Mixer Granulator?
High shear granulator finds extensive application in the pharmaceutical industry to convert fine heterogeneous powders to uniform blend of granules having larger size and density.
This boosts flow and compactability tablet procedures.
In addition, high shear mixers aid in the granulation of highly cohesive ingredients having hydrophilic polymers which is not attainable with low shear granulators.
23. Which High Shear Mixer Granulator Features increase Efficiency of Granulation Process?
The speeds of the impeller and chopper, control of flow rate of sensitive liquid coupled with torque of the impeller aids in controlling the granulation process.
The right blend of these distinctive parameters values will dictate the nucleation and coalescence, and thus the efficiency of the granulation process.
In addition, the design of the high shear granulator impeller is also another crucial component in ensuring efficient granulation process.
The machine does the dry mixing and wet granulation through basic design of the unique four blades of the blending impeller.
A perfectly designed impeller ensures that the mixing operation runs without altering the pressure zone within the volume of blending product.
Another instrumental feature is the chopper.
Independently steered choppers can effectively amplify the mixing process specifically when you add granulation fluid or paste material.
During the process of humidifying and granulating the products, the chopper controls and modulates the granules structure and granular spectrum.
It will depend on the chopper shape, product and time.
24. Why invest in SaintyCo High Shear Mixer Granulator?
SaintyCo has been supplying high shear granulator equipment for decades now.
We are knowledgeable in granulation and drying processes for different.
This consists of small capacity systems modeled for R&D and industrial size machinery for continuous and batch manufacturing of pharmaceutical products under cGMP standards.
Having established a credible reputation in the pharmaceutical sector, SaintyCo offers the best solutions for your operations: no other supplier can rival our range of High shear granulators.