Pilot-Scale Granulation Line

Precision, Flexibility, and Repeatability

Deliver consistent, high-quality granules across a wide range of formulations with closed-loop control and recipe-driven operation. Modular tooling allows quick changeover between wet granulation, melt granulation, and dry granulation workflows.

Advanced Materials Handling

All product-contact parts are made from corrosion-resistant 316L stainless steel with optional Hastelloy for aggressive chemistries. Tool-less disassembly and smooth, crevice-free surfaces ensure GMP-compliant cleaning and minimize cross-contamination risk.

Smart Process Control

Integrated HMI/PLC with real-time monitoring of torque, granule moisture, binder feed rate, and product temperature. Optional PAT tools (NIR/inline particle size, torque rheology) support data-driven decisions, QbD, and validated scale-up.

Energy-Efficient, Low Footprint

Optimized drives and variable frequency control reduce energy consumption while maintaining throughput. The compact skid-mounted design fits standard lab spaces and mobile pilot areas without compromising performance.

Rapid Scale-Up Path

Geometrically similar process modules and validated scale-up correlations enable reliable transfer of CPPs and CQAs from pilot to production. Recipe portability reduces time-to-market and mitigates scale-up risk.

Application Areas

Building Materials and Additives

Mineral fillers, cement additives, gypsum modifiers, pigment granules for improved handling and dispersion.

Furniture and Wood Composites

Wood-plastic composites (WPC), flame-retardant masterbatches, additives for surface durability and VOC control.

Automotive and E-Mobility

Polymer masterbatches, battery material pre-granulation, friction modifiers, lightweight composite additives.

Chemicals and Specialty Materials

Catalysts, molecular sieve precursors, agrochemical granules, detergent and surfactant pellets.

Pharmaceuticals and Nutraceuticals

Wet and melt granulation for solid dosage development, taste-masked nutraceutical blends, continuous processing trials.

Food and Feed

Microencapsulated flavors, vitamin premixes, trace mineral blends, functional feed additives.

Technical Specifications

Core Performance

Throughput (pilot mode): 5–50 kg/h, recipe and formulation dependent
Granule size range: 0.2–3.0 mm (with exchangeable screens/rollers)
Moisture/binder control: ±0.5% moisture accuracy with mass flow and peristaltic dosing
Temperature control: Jacketed mixer and melt zones 20–180 °C

Process Modules (Configurable)

High-shear mixer-granulator with top/bottom spray lance
Twin-screw wet/melt granulator with segmented barrels
Roller compactor for dry granulation with vacuum de-aeration
Fluid-bed dryer or inline convective dryer
Screening and conditioning unit with low-shear classifier
CIP-ready design with validated rinse and inspection points

Automation and Data

HMI/PLC: 10″ touch panel, recipe management, alarm logs
PAT options: NIR moisture, inline particle sizing, torque/pressure trending
Connectivity: OPC UA, Modbus TCP, CSV batch export, e-signature ready

Utilities and Energy

Power: 380–480 V, 50/60 Hz, 3-phase
Installed power: 8–18 kW (configuration dependent)
Compressed air: 6–8 bar, <200 L/min typical
Binder feed: 0.1–5.0 L/min, closed-loop
Exhaust/vent: 300–600 m³/h with HEPA option

Materials and Compliance

Product contact: 316L SS, Ra ≤ 0.6 μm; optional Hastelloy C-22
Seals/gaskets: FDA-compliant elastomers
cGMP-ready, CE marked; documentation for IQ/OQ available

Customer Case

User Recognition

Proven Market Performance

Adoption by top-20 chemical and pharma R&D centers for rapid prototyping and DoE campaigns.
Demonstrated 25–40% reduction in development cycles by leveraging PAT-driven optimization and recipe portability.

Customer Feedback

“Setup to first validated batch in under four hours—unmatched changeover speed.”
“PAT integration made scale-up predictable; CQAs held within spec at 10× throughput.”
“Cleaning is genuinely tool-less. We cut downtime and reduced cross-contamination risk.”

Representative Case Studies

Specialty Chemicals: Converted a hygroscopic powder to free-flowing granules, reducing dust by 85% and improving dosing accuracy by 30%.
Nutraceuticals: Achieved uniform taste-masked granules with ±3% API content uniformity, enabling direct compression.
Automotive Composites: Produced WPC masterbatch pellets with 15% lower energy use and superior dispersion in downstream extrusion.

Others

Why It Wins

Innovation and Competitive Edge

True multi-mode granulation on a single, modular platform.
Deep PAT integration for QbD, real-time release testing readiness, and defensible scale-up.
Compact, efficient, and compliance-ready—ideal for Google-ready product pages targeting high-intent searches in pilot granulation and small-batch manufacturing.

Pilot-Scale Granulation Line