Fluid bed processors (FBP) are widely used in manufacturing industries, including pharmaceuticals, nutraceutical, food and agrochemicals, for processes such as drying, granulation and coating. Several critical process parameters significantly influence the performance and efficiency of the FBP. Understanding and controlling critical parameters is essential for achieving the desired product quality and operational efficiency. Below are the key process parameters that play a crucial role in the optimisation of Fluidised Bed Processors:

1. Inlet Air Velocity

Impact: The velocity of the air entering the fluidised bed is fundamental to the fluidisation of particles. Maintaining proper air velocity ensures that particles remain in the desired fluidization regime, which is critical for efficient processing.

Control Measures: Control can be achieved through monitoring CFM (cubic feet per minute) velocity, adjusting blower speed, and regulating the percentage of blower opening.

2. Inlet Air Temperature

Impact: The temperature of the incoming air is a crucial factor in the drying and coating processes within the fluidised bed. Correct temperature settings are essential to achieve the desired product characteristics without causing overheating or underheating.

Control Measures: Accurate temperature controls using sensors and setting up the range of processing temperatures are necessary to ensure optimal conditions for an efficient coating process and then drying and curing stages.

3. Inlet Air Humidity and Dew Point

Impact: The humidity and dew point of the inlet air influence the evaporation efficiency and the stability of moisture-sensitive drugs.

Control Measures: anish machines incorporate advanced dehumidification systems capable of lowering the dew point significantly, enhancing evaporation efficiency and improving the stability of low-moisture products.

4. Bed Height

Impact: The height of the fluidised bed affects the residence time of particles, influencing the efficiency of drying & coating processes.

Control Measures: Optimal column and bed height settings are essential for achieving particle flow fluid dynamics and desired final parameters for processing.

5. Particle Size Distribution

Impact: The size and distribution of particles within the fluidised bed affect fluidisation behaviour and overall process efficiency.

Control Measures: Consistent particle size distribution helps maintain uniform fluidisation and process efficiency.

6. Material Characteristics

Impact: Properties such as density, particle shape, and moisture content of the materials being processed influence fluidisation and product quality.

Control Measures: Understanding material characteristics helps in tailoring process parameters to achieve optimal performance.

7. Fluidization Regime

Impact: The choice of fluidisation regime (e.g., bubbling, turbulent) affects particle-fluid contact, influencing heat and mass transfer and coating efficiency.

Control Measures: Selecting the appropriate fluidisation regime, in combination with ADP plate configuration and mesh size, ensures effective processing.

8. Spraying Configuration

Impact: The configuration of the spraying system is vital for the quality and uniformity of coated or granulated particles.

Control Measures: Different spraying configurations (bottom spray, top spray, tangential spray, hot melt spray) offer specific advantages that can be optimised based on product characteristics.

9. Spraying Gun Type and Nozzle

Impact: The type of spraying gun, nozzle and parameters such as spray rate & nozzle atomising pressure significantly influence coating and granulation processes.

Control Measures: Adjusting peristaltic pump RPM, tubing size, nozzle orifice, and atomising pressure ensures precise control over the spraying process.

10. Drying Time

Impact: The drying duration directly impacts the final product’s moisture content.

Control Measures: Proper control of drying time is crucial for achieving the desired product characteristics.

11. Finger Bag Size and Retention Mesh Size

Impact: The choice of finger bags and retention mesh can enhance evaporation and improve yields.

Control Measures: Consulting with technical experts to select appropriate finger bags and retention mesh based on product particle size is essential.

12. Batch Size Relation

Impact: The relationship between the starting load of processing material and the final batch size, machine capacity, and product density affects process efficiency.

Control Measures: Optimising batch size in relation to machine capacity ensures efficient processing.

13. Exhaust Air Flow Rate

Impact: The exhaust air flow rate influences the overall mass balance within the system and can impact drying and product quality.

Control Measures: Monitoring and adjusting the exhaust air flow rate is crucial for maintaining desired conditions.

14. Instrumentation and Control

Impact: The accuracy and reliability of instruments and control systems for monitoring and adjusting process parameters are critical for maintaining optimal conditions.

Control Measures: Implementing precise instrumentation and robust control systems ensures consistent process performance.

Optimising and controlling these parameters are essential to ensure the desired product quality, efficiency, and consistency in fluidised bed systems. anish pharma, with over three decades of expertise in fluid bed systems for granulation and pelletization, offers unparalleled process solutions to the pharmaceutical industry. Our full-fledged application lab supports clients at development, pilot scales, and commercial scales, enabling them to optimise these parameters effectively. With over 1,000 successful fluid bed installations across continents, anish pharma ensures seamless operation and support, delivering dependable solutions worldwide.