A Fluid Bed Dryer with a large tank and a mixer, used for drying and mixing substances.
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The Complete Guide to Understanding How Fluid Bed Dryers Work

Written by ChemiplantMarch 18, 2024

Fluid Bed Dryers are used to dry, wet granulated materials attained after the granulation process. The material is dried through the combination of (a) moisture diffusion from the inside of the granules and (b) the removal of moisture by forced-air convection. In this unit operation, the granulated material is fluidized by hot & dehumidified air to achieve efficient heat and mass transfer.

There are three critical inlet air parameters that affect the efficiency of the Process and the Quality of the product:

  • Temperature
  • Humidity
  • Air Flow Rate

Features:

  • Mono block construction – retarding chamber and filter bag chamber made in a single-piece construction to enhance GMP & promote hygienic cleaning.
  • Solid Flow Sensor installed to detect leaks on filter bags to avoid material loss & air contamination.
  • Intrinsically safe earthing arrangement.
  • Inlet air-filtration system with primary. secondary and 0.3 microns HEPA filters.
  • Pneumatic lifting/locking for product container with retarding chamber.
  • Fully Automatic Bag shaking.
  • Rear Chamber with heating coils and Inlet filter is to be mounted in the Technical Area (Remote Area) 
  • Blower/Motor to be mounted in the Technical Area (Remote Area)
  • Inlet & Outlet dampers with pneumatic control valves.
  • PLC-based control panels with Time vs. temperature, Control Batch Programming & batch data printouts.

Working Principles:

Fluid Bed Dryer is a batch operation in which the moist material is converted to a free-flowing fluidized state by means of an upward-flowing hot air stream. During this process, the entire surface of each particle is surrounded by hot air thus achieving a homogeneous distribution of temperature & thereby a rapid drying operation.

The air is drawn through a blower fan from outside & passed through 3 stages of filtration (pre, fine & HEPA) & heated with the help of steam coils & or electric heaters. The air then flows upwards through the material Inside the product container & absorbs the moisture from the material.

The filter bag assembly mounted above the container & retarding chamber keeps the material caught up in the flow of air which subsequently fall back into the container, by means of the outlet air damper as installed in the outlet duct.

The drying time depends on various factors such as physical properties of raw material, initial moisture content, type of moisture (free or inherent of water of crystallization) & the drying temperature.

Accessories:

  • Retarding Chamber:

During the FBD operation, there is a tendency of generation of static electricity due to the agitation of material and the presence of steam & dust. However, the same is variable in quantity depending upon the material air velocity & the degree of dryness of the product. The retarding chamber is provided to settle the heavier particles in the product container. Also, outside the retarding chamber antistatic probe assembly is provided to absorb static electricity and to discharge the same to the earthling cable.

  • Filter Bag & Sealing:

The filter bag is sealed with the help of an inflatable gasket held inside a SS ring which is inserted into the lower end of the filter bag & sandwiched between the retarding chamber & the filter housing The gasket material can be Silicon, Neoprene, or EPDM Food Grade rubbers. The basic function of the sealing is to prevent the product from escaping into the outlet air.

  • Filter Bag Shaking Device:

The device is used for the removal of fine particles from the Filter Bag & thereby avoiding pressure drops across the filter. It consists of a wire rope & pulleys wherein one end of the wire rope is attached to a handle and the other end to the filter bag hanger. The filter hanger is held in place by the handle stopper & whenever the handle is released, jacked up & down the filter bag is compressed & stretched alternately. This operation can also be automated by means of a pneumatic cylinder.

Conclusion:

In conclusion, fluid bed dryers are crucial for drying wet granulated materials efficiently. They operate by fluidizing the material with hot, dehumidified air, allowing for effective heat and mass transfer. The key parameters affecting the process efficiency and product quality include temperature, humidity, and airflow rate. The design features of fluid bed dryers, such as mono block construction, solid flow sensor, and inlet air-filtration system, enhance their performance and hygiene. The working principle involves converting moist material into a free-flowing fluidized state using an upward-flowing hot air stream. Accessories like the retarding chamber, filter bag & sealing, and filter bag shaking device further optimize the drying process and ensure product quality. Overall, fluid bed dryers are essential in various industries for their rapid and efficient drying capabilities.

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Industrial drum blender designed by Chemiplant Engineering for efficient mixing processes.
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Advantages of Incorporating a Drum Blender in Pharmaceutical Manufacturing

Written by ChemiplantMarch 18, 2024

Chemiplant Engineering Company Drum Blenders are industrial mixing devices used to blend dry powders and granules uniformly. Their application extends across various industries, including pharmaceuticals, food processing, chemicals, minerals and mining, and cosmetics.

Here are the key applications of drum blenders:

  • Pharmaceutical Industry: Drum blenders are extensively used in the pharmaceutical industry for blending dry powders and granules used in the production of tablets, capsules, and other pharmaceutical products.
  • Food Processing: In the food processing industry, drum blenders are used for blending a wide range of ingredients such as flour, spices, sugar, and additives. Drum blenders ensure thorough mixing, essential for achieving consistent product quality and flavor.
  • Chemical Industry: Drum blenders play a crucial role in the chemical industry for mixing dry chemicals and compounds. They are used in the production of various chemical products, including detergents, fertilizers, and industrial chemicals, ensuring uniform blending and consistent product quality.
  • Minerals and Mining: Drum blenders are used in the minerals and mining industry for blending powders and granules used in the production of minerals and mining products. They are particularly useful for blending different grades of minerals to achieve the desired product specifications.
  • Cosmetics Industry: In the cosmetics industry, drum blenders are used for blending cosmetic powders, pigments, and other ingredients used in the production of cosmetics. Drum blenders ensure uniform blending, which is essential for achieving consistent product quality and appearance

The advantages of incorporating a drum blender into pharmaceutical manufacturing processes

  • Convenient Blending Containers:

Drum blenders serve as highly convenient blending containers due to their design. They allow for easy loading and unloading of materials, minimizing the need for manual handling. This feature reduces the risk of contamination and ensures product safety, a critical factor in pharmaceutical manufacturing.

  • Flexible Installation Options:

Drum blenders can be installed as free-standing units or integrated into existing processing lines through wall installations. This flexibility in installation allows manufacturers to adapt the blending equipment to suit their specific production needs and facility layout.

  • Ease of Handling:

Drum blenders are designed for easy handling, requiring minimal manual intervention. This ease of handling streamlines the blending process, reducing the risk of operator errors and improving overall efficiency.

  • Enhanced Blending Performance:

Drum blenders offer a good blending performance, ensuring thorough mixing of powders and granules. The tumbling action of the drum facilitates efficient blending, resulting in a homogeneous blend with consistent quality.

  • Large Capacity Range:

Drum blenders are available in a wide range of capacities, with some models offering a maximum capacity of up to 750 liters. This flexibility in capacity allows manufacturers to choose a drum blender that meets their production requirements, whether they need to blend small or large batches of materials.

  • Homogeneous Mixing:

Drum blenders ensure uniform blending of ingredients, leading to consistent product quality. The gentle tumbling action of the drum prevents segregation of particles, ensuring a homogeneous blend.

  • Reduced Processing Time:

Drum blenders are designed to efficiently blend large batches of materials, reducing processing time compared to manual or less efficient blending methods. This results in increased production output and cost savings.

  • Cost-Effective:

Despite their advanced blending capabilities, drum blenders are cost-effective compared to other high-end blending equipment. This makes them an attractive option for pharmaceutical manufacturers looking to improve their blending processes without breaking the bank.

Conclusion

In conclusion, incorporating a drum blender into pharmaceutical manufacturing operations offers numerous advantages, including versatility in applications, convenient blending containers, economical solutions, flexible installation options, ease of handling, enhanced blending performance, and a large capacity range. Pharmaceutical manufacturers can benefit significantly from the efficiency and reliability that drum blenders bring to their blending processes.

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