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Granulationline CGS

Compact efficiency for the production of tablet granules.

Abbildung DIOSNA

Compact Granulation System CGS at a glance

· Reduction of the project and operating costs
· Smooth and quick product transfer
· Minimum installation area
· Process safety and excellent containment
· Simple to operate and excellently planned component accessibility

Description of the Granulationline CGS

The DIOSNA Compact Granulation System CGS combines the process steps mixing, granulating and drying in one compact granulation unit. It provides accelerated product transfer and reduced GMP space requirements.
Wet granulation of pharmaceutical tablet mixtures with subsequent fluid bed drying is a basic step in the production of solid dosage forms. The CGS concept provides optimal integration of the process steps of mixing, granulating and drying. The outlet of the mixer-granulator is directly linked to the inlet of the fluid bed dryer, eliminating long transfer pipes. Thus product contact surfaces are minimised and the yield is increased. Even sticky granules which are difficult to transport by pneumatic conveying can be transferred easily and quickly into the dryer.

Installation expenditure for the CGS is low. Mixer and dryer are supported by one common frame which makes additional framework unnecessary. The operating media are supplied through-the-wall from the technical zone.

If solvent based formulations are to be produced, special attention must be given to explosion protection. The CGS concept can incorporate an integrated explosion protection concept. The individual processing units of mixer, wet mill and dryer will then be designed to be 12 bar pressure shock resistant. Due to the short and direct connection between the mixer and the dryer the normally required explosion protection valve between the single elements can be omitted. This considerably reduces the cost, set-up times and maintenance.

Due to the compact installation, the floor space required by the CGS plant is very small. This fact is not only important for existing plants with limited available space, but also for new plants which allows clean room space to be reduced. Since the size of the cleanroom area influences not only the operating costs but also the investment cost, the CGS concept offers considerable potential for reducing the overall project capital and running costs.

From feeding the mixer to discharging the dryer into an IBC, product transfer is completely enclosed. The CGS can be upgraded with all necessary options to meet even the highest containment requirements for the production of highly-potent substances. The upgrade package ranges from the integration of containment valves for charging and discharging interfaces to WIP/CIP design of the plant.

The mixer-granulator and the fluid bed dryer are installed on a common frame and are connected by an integrated operator platform. Peripheral components such as wet mill and vacuum conveying system with dry mill are integrated into the plant allowing ergonomic access for inspection, maintenance and cleaning. As an example the screens of the mills and the filters of the pneumatic conveying system can be easily changed from the platform without additional tools. Due to the optimal ergonomic design, the CGS can be set up and operated by one single operator.

All connection lines of the CGS from feeding the mixer to discharging the dryer are integrated into the automatic cleaning system. Due to well planned accessibility of all areas the supply lines can be connected in minimal time. Nearly all components are subjected to the automated cleaning. In the case of a WIP-design of the plant the main contamination is removed in the course by a pre-cleaning process and fine dust is trapped without opening the equipment. In the second stage, critical components such as the product filter of the fluid bed dryer can be dismantled safely. Of course the CGS can be upgraded to a full CIP concept, using DIOSNA’s patented CIP filter cleaning system.