#fluidized bed processor

Introduction:

The pharmaceutical industry is constantly evolving, seeking innovative solutions to enhance manufacturing processes and produce high-quality products. One such groundbreaking technology that has revolutionized pharmaceutical manufacturing is the Fluid Bed Processor (FBP) – a versatile and efficient tool used for granulation. In this blog post, we will delve into the world of FBP, exploring its capabilities, benefits, and its indispensable role in modern granulation processes. Let's explore how FBP is changing the game for pharmaceutical manufacturers and why FBD Fluid Bed Dryers are at the forefront of innovation.

Understanding Fluid Bed Processors (FBP)

Fluid Bed Processors are equipment designed to handle solid materials in granular or powder form, providing precise control over various processes like drying, granulation, coating, and pelletization. The principle behind FBP lies in suspending the particles in a heated air stream, creating a fluidized state, which enables uniform and efficient processing of the materials.

The Advantages of Fluid Bed Processor in Granulation

Enhanced Granule Properties

FBP ensures consistent and uniform mixing, resulting in granules with controlled particle size and improved flow properties. This uniformity directly translates into improved drug content uniformity, dissolution, and compressibility, ensuring the final product meets stringent quality standards.

Efficient Drying Capabilities

FBP plays a crucial role in the drying process after granulation. By employing FBD Fluid Bed Dryers, pharmaceutical manufacturers can achieve rapid and efficient drying, as the fluidized state allows for enhanced heat and mass transfer. This translates into reduced processing time, lower energy consumption, and ultimately, cost savings.

Flexibility and Scale-Up Capabilities

Fluid Bed Processors offer remarkable flexibility in accommodating various batch sizes. The same equipment can be easily adapted for small-scale research and development batches as well as large-scale commercial production. This scalability is highly advantageous for pharmaceutical companies, as it allows seamless progression from lab-scale to full-scale production.

Key Applications of Fluid Bed Processors in Pharma Manufacturing

Granulation

Granulation is a crucial step in pharmaceutical manufacturing, as it enhances the flow and compression properties of the drug formulation. FBP provides a highly efficient and consistent method for granule formation, leading to improved drug product performance.

Drying

Fbd fluid bed dryer are widely used for drying wet granules or granulated material. The fluidized state ensures that the drying air comes into direct contact with all particles, resulting in uniform and rapid drying.

Coating and Pelletization

FBPs are also employed in pharmaceutical coating processes, where a thin layer of coating material is applied to the granules. Additionally, fluid bed pelletization is used to create spherical pellets, ideal for controlled-release formulations.

Future Innovations in Fluid Bed Processing

As pharmaceutical manufacturing continues to evolve, so does the technology surrounding FBP. Manufacturers are constantly investing in research and development to enhance fluid bed processors further. Advancements include sophisticated process control systems, better integration with other manufacturing processes, and improved energy efficiency.

Conclusion:

Fluid Bed Processors have become a game-changer in the pharmaceutical manufacturing industry, particularly in the context of granulation processes. Their ability to provide uniform and consistent granules, efficient drying, and scalability makes them indispensable tools for pharmaceutical companies striving to deliver high-quality products to patients worldwide.

As innovations continue, we can expect fluid bed processing technology to further revolutionize the pharmaceutical industry, driving it toward a more efficient and sustainable future.

Many new and improved technologies and machinery have been developed over the years as a result of technological advancements. In manufacturing, this has led to the development of more effective and efficient production procedures and systems. The plethysmometer, for example, is a device that uses water displacement to measure an object's volume. To measure the volume of liquids and gases, this equipment is commonly employed in the manufacturing sector.

In addition, there is a tablet coater, a machine that coats tablets with a thin layer of substance. Pills and tablets are coated with a layer of medicine or other substance using this equipment.

It is also employed in the pharmaceutical industry, where pellets are formed.

Despite recent advances in technology, manufacturing remains a vital component of many sectors. Manufacturing has become more critical than ever before. Technology has had a significant impact on manufacturing in recent years, and the following article examines five of these trends.

Manufacturing processes have become more efficient as a result of technological advancements.

Because of the advances in technology, it is now possible to produce items that have reduced environmental footprints.

The use of technology in the production process has made it easier for workers to communicate and collaborate.

New and creative production procedures have been developed as a result of technological advancements.

Manufacturing has become more accessible to a worldwide market because of advances in technology. The drying fumes carry away the evaporated liquid. In some cases, the exhaust gas is partially recycled to save energy. double cone blender, plethysmometer are also available from VJ Instruments. 

 What is a plethysmometer used for?

Pneumothorax, or lung volume, is the most common organ to be measured with a plethysmometer. Blood flow and blood pressure can also be measured using this device. An electronic tablet coater is a piece of equipment used to apply a thin layer of material to an electronic tablet. It is a machine that pelletizes materials, often a powder or granular materials, that are difficult to compress into a solid mass. To determine the volume of an object, scientists utilize a scientific device called a plethysmometer. Determine a person's lung capacity, it is frequently employed in medical research. A tablet coater is a machine that applies a thin layer of substance to tablets before they are packaged. Use this to preserve the pill from fracture, as well as for medication dosing control. The powder is compressed into small pellets using a pelletizing machine. Metals and polymers are frequently subjected to this treatment to facilitate their handling and transportation.

To measure volume, a plethysmometer submerges an object in the water and reads the volume of the displaced fluid.

Coating tablets with a layer of the thin film is done by using a tablet coater machine. Increasing the tablet's stability and shelf life is often done. Compressing powder into pellets is the function of a pelletizing machine. Pharmaceuticals and other products that must be kept in a compact shape are common examples of this practice. VJ Instruments also provides fluid bed processor.

 What is the process of using a tablet coater?

The phenomenon is measured with a plethysmometer. Phethysm is the change in volume of an organ or region of the body as the blood flow to that area increases or decreases.

Numerous medical facilities and research laboratories, as well as sports medicine facilities, employ plethysmometers to monitor blood flow. Plethysmometers come in a variety of shapes and sizes, each with a distinct function. When it comes to measuring changes in limb volume, some plethysmometers are better suited for this task than others. Tablet coating machines are used to apply a layer of coating material on tablets. To enhance the look, taste, and/or durability of tablets, a coating is applied. VJ Instruments is the best fluid bed dryer manufacturer.

 Conclusion

A tablet coater is a piece of equipment used to apply a thin layer of coating to tablets. Tablet coatings can enhance the tablet's appearance, increase its resistance to environmental factors, or alter the tablet's release properties.

Full fluidization is guaranteed with the unique revolutionary swirl generating method which gives great uniformity of coverage and high returns to the end product. The major difficulty is how optimal and uniform granule covering may be achieved. All grains engaged in the process of coating should have the same coating thickness, irrespective of their size.

In addition to handling aqueous as well as organic film coating systems, an advanced control panel helps you to monitor and record all the settings for the Fluid bed processor.

The chamber generally is a vertical cylinder in a fluidized bed processor. A column of air that flows up from the lower center of the cylinders fluidizes the pellets. The tablets in the center travel upward and downwards through the chamber wall, from the base of the column into the air stream again. In the base and top of the chamber, there are spray nozzles used to insert the coating solution.

The core of the pellet is fragile, abrasive, and tearing-prone, which makes it difficult even under optimal conditions to completely coat the tablet. This is due to the tablet-to-tablet collision as well as the contact between the tablet chamber and the tablet.

Two main configurations are utilized to implement fine tablet coating solutions:

1.    High-Pressure Airless System

Airless spray fluid is pushed into a small orifice between 0.02 and 0.2 mm in diameter at the high pressure of 1.7 to 20 MPa (250 to 3000 Psi) to produce a fine spray. The atomization degree and the spray rate are all regulated by fluid pressure, viscosity, and size of the aperture.

2.    Low-Pressure Atomized Air Systems

The liquid is pushed through a wider opening between 0.05 and 2.5 mm in diameter with a relatively low pressure of 35 – 350 kPa (5 to 50 psi). At the top of the atomizer, the low-pressure air reaches the liquid stream and a finely distributed spray pattern is created. The degree of atomization is determined by the size of the aperture, fluid viscosity, fluid pressure, air cap design, and air pressure.

  Operation 

1.    Bottom-Spray Coating (Wurster coating)

This processing option uses the energy and controls the fluidized bed processor to create a pneumatic mass transport inside a special insert, which is consisted of a perforated bottom screen with defined free areas.

This uniform statistical residence time of all particles in the coating zone results in a very uniform coating. Due to the high kinetic energy provided by the pneumatic mass flow moist particles are separated, as such allowing the individual coating of even very small particles. Due to the nozzle being positioned directly inside the product and concurrently spraying a premature viscosity change of the coating droplet is avoided. All these features result in the highest possible coating quality, which is imperatively required to produce defined and reproducible drug delivery profiles.

2.    Top-Spray Coating

Spray coating can be used for all fluid bed systems, be it in batch or continuous operation or if the film is applied from a sprayed solution or suspension. For this processing option from the parameters has to be chosen to avoid agglomeration, i.e. liquid bridges between the air suspended particles.

This is the most extensively used tablet coating technique in the pharmaceutical industry. It personifies the tablet with different dyes and helps to stabilize the chemical compound. The unpleasant smell and taste of the pill are also masked.

The film coating technique includes placing film solutions on tablets through a sprayer. This procedure is done once with a polymer, plasticizer, solvent, and dye solution.

The pills are sprayed and quickly dried in a rotating tablet pan. After drying, a thin coating of polymer is created around a tablet. The tablet can sometimes keep its color; however, this can be adjusted if the solution is mixed with various dyes.

There are now numerous varieties of tablet coating machines on the market. The following are the three main categories.

Standard Pan

Perforated Pan

Fluidized Bed Processor

Film Coating Process

A polymer is dissolved in a solvent as well as other materials such as plasticizers, dyes, and pigments and sprayed into the tablet coater.

You must put the tablets periodically into the coating pan to conduct the film coating. Measure the distance between the spray nozzle and tablet bed precisely and appropriate adjustments for even layering over the bed.

The coating solution may normally atomize to very thin droplets. As the coating pan spins with the tablets, the sprayer will disperse the coating solution on the bed.

Tablet coating machines are used to cover the tablet surface with a thin film layer. The film is mostly used for:

1.      Hide the pill's color, flavor, and odor.

2.      Protection against physical or chemical damage to the drug.

3.      Regulate the medication's release.

4.      prevent the medicine from disintegration by digestive fluids.

5.      Enhance the tablet look - make the product more attractive.

6.      Include medicines or ingredients in the layer to prevent incompatibility with chemical products.

Tablet coating machines operate on the basic premise of applying coating materials to a set of tablets in a bed that may move horizontally or vertically. A simultaneous airflow allows the solvent to evaporate. The coating is spread uniformly throughout the tablets by the bed's movement.

There are now numerous varieties of tablet coating machines on the market. The following are the three main categories.

 1.  Standard Pan

This comprises an approximately 15 to 200 cm (6 to 80 centimeters) diameter circular metal pan that is inclined on a tabletop stand. An electric motor can be used to rotate the pan.

The panel is configured to rotate after loading a batch of tablets. The movement of the tablets leads them to tumble within the pan. In the rotating tablet bed, the coating solution is sprayed in atomized form, which generates a quick and equal distribution.

Drying efficiency may be accomplished easily by:

       I.          The immersion sword - the drying air is spread through a perforated metal sword immersed in the bed.

     II.          Using a baffled pan and diffuser enables the consistent dispersion of dried air throughout the surface of the tablet.

    III.          An immersion tube system - the tube is submerged in the bed and provides hot air via the spray nozzle.

 2.  Perforated Pan

This equipment is composed of a partly or fully perforated drum, which rotates on its horizontal axis and the complete system is enclosed in a sealed housing.

The coating solution is applied through spray nozzles inside the tank in all perforated pan systems.

 3.  Fluidized Bed System

The chamber generally is a vertical cylinder in a fluidized bed processor. A column of air that flows up from the lower center of the cylinders fluidizes the pellets. The tablets in the center travel upward and downwards through the chamber wall, from the base of the column into the air stream again. In the base and top of the chamber, there are spray nozzles used to insert the coating solution.

The core of the pellet is fragile, abrasive, and tearing-prone, which makes it difficult even under optimal conditions to completely coat the tablet. This is due to the tablet-to-tablet collision as well as the contact between the tablet chamber and the tablet.

Two main configurations are utilized to implement fine tablet coating solutions:

     I.        High-Pressure Airless System

Airless spray fluid is pushed into a small orifice between 0.02 and 0.2 mm in diameter at the high pressure of 1.7 to 20 MPa (250 to 3000 Psi) to produce a fine spray. The atomization degree and the spray rate are all regulated by fluid pressure, viscosity, and size of the aperture.

    II.        Low-Pressure Atomized Air Systems