High-efficiency Wet Mixing Granulator Machine

Working Principle

The high-efficiency wet mixing granulator primarily mixes powdered active and excipient materials with a binder to form a wet mass, which is then granulated into uniformly dispersed particles with consistent size distribution. It is widely used in pharmaceutical and food industries for mixing and granulating raw materials. The system is highly integrated with PLC and variable frequency drive(VFD) control technology, ensuring full compliance with current cGMP standards. 

Process Workflow

Vacuum Feeding: 

• The powdered materials are conveyed into the mixing chamber via a vacuum transfer system. 

• A vacuum source, connected through a pressure-resistant steel wire hose and a filter on the vessel lid, evacuates air from the sealed chamber. 

• Under negative pressure, the powder is rapidly drawn into the chamber. 

• Once feeding is complete, the inlet valve closes, the exhaust valve opens, and the bottom agitator starts. 

Mixing Phase:

• Initially, the agitator operates at low speed for brief pre-mixing. 

• The speed then increases for high-intensity mixing. 

• The material at the bottom is propelled upward along the agitator’s helical surface due to centrifugal force. 

• Upon reaching the curved vessel wall, the material is redirected downward by combined thrust and compression forces. 

• When hitting the upper conical section, the material reverses direction, flowing back toward the center before falling to the bottom, creating a continuous cycling motion. 

Fluidized Mixing & Spray Granulation:

• This dynamic process ensures thorough mixing through continuous tumbling, shearing, and rotational fluidization. 

• Once homogeneity is achieved, the automated control system activates the spray function.

• Purified compressed air pressurizes the binder solution from the storage tank, delivering it to the spray nozzle mounted on the vessel lid. 

• The binder is atomized into a fine mist and evenly sprayed onto the powder bed. 

Wet Mass Formation & Granulation:

• As the binder is added, the fluidized material gradually moistens, forming a wet mass(soft material).

• A high-speed chopper, horizontally mounted on the vessel wall, works in tandem with the agitator to generate turbulent vortex flow. 

• The material undergoes intense three-dimensional movement-tumbling, colliding, and shearing-resulting in uniform particle refinement.

• This process promotes spherical granule formation with high density and stability. 

Discharge:

• After granulation, the agitator switches to low-speed intermittent rotation. 

• The discharge valve opens, allowing the wet granules to exit through the outlet into a wet milling system for further processing. 

This integrated approach ensures efficient, homogeneous granulation with minimal manual intervention, significantly enhancing productivity while meeting stringent pharmaceutical and food industry standards. 

Key Features

• Horizontal Cylinder Design: Optimized structure for efficient mixing and granulation. 

• Pneumatic-sealed Drive Shaft: Allows switching to water during cleaning for enhanced hygiene. 

• Fluidized Granulation Technology: Produces highly spherical granules with excellent flowability. 

• Reduced Binder Usage: Cuts binder consumption by 25% compared to traditional methods, shortening drying time. 

• High-speed Processing:

(1) Dry mixing: 2 minutes per batch.

(2) Granulation: 1-4 minutes per batch. 

(3) 4-5 faster than conventional processes. 

• Fully Integrated Process: Drying mixing, wet mixing, and granulation performed in a single closed vessel. 

• cGMP Compliance: Equipped with strict safety controls to meet pharmaceutical manufacturing standards. 

Technical Specifications