Fluid Bed Dryer Developer

    Fluid Bed Dryer Developer

    ESSICCA DEVELOPER

    INTRODUCTION

    Fluid-bed drying is a commonly-used process in the pharmaceutical industry due to its high/y efficient drying of granulated materials obtained by wet granulation (High Shear MIC)
    The drying of granulated materials is achieved through a combination Of moisture diffusion from the solid material to the heated air stream and the removal Of that moisture by forced-air convection.

    PROCESS CONCEPT

    The ESS/CCA dryer uses control systems, influenced by specific drying programs, which eliminates problems related to the interaction of solid particles with a gas that are typified by:

    - The formation of air channels within the granulated mass
    - The lack of uniformity in the drying process
    - Localized overheating of the granulation in some parts of the bed attrition of the granulation as it dries

    Features

  • PLC Siemens, with coloured Touch Screen panel.
  • Top Spray - Bottom Spray.
  • Automatic air channel elimination.
  • Vacuum loading system.
  • Electric system according ATEX rules.
  • In Wall design concept.
  • Entirely dismantle.
  • According to GMP guidelines.
  • FAT - SAT - Validation Documents.
  • DRYING PROGRAM

    ESSICCA is equipped with software that allows diferent drying programs to be selected depending on the nature of the material being dried.

    Examples Of possible drying programs include:
    - Constant air flow and product temperature
    - Using progressive air flow that changes with time
    - Using immediate fluidization
    - Using controlled fluidization determined by temperature gradient

    ESSICCA can measure 7 (seven) parameters at the same time during the process:

    - In/ct air temperatura: Ti
    - Temperature ofthe air in contact with granulated material: Tp
    - Exhaust air temperature: Te
    - Pressure within the expansion chamber: Pce
    - Pressure in the plenum.. Pp
    - Pressure at the exhaust.. Pe
    - Air flow: Q

    Measurements are constantly processed by means of a PLC which provides information based on the selected drying program.

    DRYER FEATURES

    Process outputs from ESSICCA:

    - Drying Kinetics
    - Drying END POINT
    - Drying Time and Efficiency
    - Effect of air now on the characteñstics of the granulated material

    DRYING PROCESS KINETICS

    cinetica-de-secado


    The moisture content of the granulated product decreases exponentially, reaching 2% after 25 minutes of drying

    DETERMINATION OF END POINT OF THE DRYING PROCESS

    determinacion-del-punto-final-de-secado


    The granulated products (l and ll) with same composition but granulated with different quantities of water, reached to 2% of moisture content end point at the same product temperature but different drying times.

    DRYING PROCESS: TIME AND EFFICIENCY

    tiempo-y-eficiencia-de-secado


    Time and efficiency of the drying process vs. kg of granulated product to be dried

    AIRFLOW AND ATTRITION OF THE GRANULATED PRODUCT

    caudal-del-aire-y-atricion-del-granulado


    Particle size distribution of the dry granulated product / airflow effect

    esquema_general

    GENERAL DIAGRAM

    -The air enters the dryer to a determined temperature, goes through the bed of granulated materials and goes out the dryer at lower temperature and higher humidity.
    -Temperature and pressure sensors monitor the changes during the whole process.





    ESSICCA is a fluid bed dryer which includes two new practica/ concepts of a great importance:

    1- Optimization of the drying process Unlike conventional fluid-bed dryers, which only allow drying air flow and temperature to be fixed, ESSICCA facilitates optimization of the drying process through application of specific drying programs as follows:

    – Avoid the formation of air channels through the product bed which can extend the process time and affect the quality of the final product.
    – Avoid localized overheating of granulated product that could ultimately affect product stability.
    – Yield uniform product moisture content at the end of the process, thus avoiding problems in subsequent manufacturing processes, such as sticking of materials to punch faces during tabletting.
    – Minimize attrition of the granulated product.


    2- Automation of drying process which means:

    – Makes the drying process independent of the operator through application of predefined recipes.
    – Automatically determines the end point of the drying process, ensuring that the moisture content of the final product meets required levels without the need to assay intermediate in-process samples.

    EXPERIMENTAL CONDITIONS

    Each drying test was conducted using a placebo granulation consisting ofAvicel PHIOI and Lactose (70:30) using different concentrations of PVP K30 as binder.
    Granulation was carried Out in a MIC high-shear mixer-granulator using different quantities of water as the granulation solvent.

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