Pilot-Scale Granulation Line

Pilot-Scale Granulation Line for R&D and Small-Batch Production

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Product Highlights

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.

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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.

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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

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Customer Case

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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.

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Others

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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.