Neuhaus Neotec 'Fluid Bed Technology' - Vision Engineers

ApplicationsMORE THAN HOT AIR:PARTICLES, PROCESSES, PARAMETERSThe fluid bed creates ideal conditions for a most intenseheat and mass transfer. A fluidized bed is formed when a gas(generally air) is passed through a quantity of solids (presentin a holding vessel) from the bottom. The solids are intenselydispersed, extending the complete surface of the solids tothe air. Thus, fluid bed drying is one of the most efficientdrying methods available. Advanced fluid bed technologiesoffer much more opportunities: By spraying liquids ontothe solids, a variety of innovative processes like granulation,agglomeration, coating and microencapsulation can be realized.Numerous processing variables and sequences providemany options for optimizing existing products (performance,handling characteristics, value, etc.), or even developing entirelynew products.HIGH EFFICIENCY DRYINGExample extrudate drying: Wet extrudates can be dried verygently and efficiently.SAVING AROMASExample lemon oil aroma: Through spray granulation and microencapsulation,liquid lemon aroma is homogeneously dispersedand embedded into a closed matrix. The final productis a dust-free, compact, UV light and oxygen-protectedaroma granule.STABILIZING VALUABLE INGREDIENTSExample enzymes: Fermented enzyme liquid is sprayed on acarrier material and gently dried, preserving the activity ofthe enzyme. The final product is a free flowing, active granulewhich is easy to handle and process.STABILIZING COMPOUNDSExample vending machine recipes: Powder mixtures of milkpowder, sugar, instant coffee and flavors are agglomerated inthe fluid bed becoming an easy to dissolve compound withdefined bulk density and minimized risk of segregation.DUST REDUCTIONExample granular pesticides: Micronized pesticides (often explosivein nature) are converted to dust-free, flowable productsthat are safe to handle and easy to dose.INSTANTIZATION OF BEVERAGE POWDERSExample instant chocolate beverages: Fine, dusty, light coloredchocolate powders, can be converted to dust-free, flowable,dark colored granules, with significantly improved dissolutionproperties.TABLETTING OF DRUGSExample pharmaceuticals: Drug formulations are granulatedin the fluid bed (prior to tabletting) to ensure a homogeneousdistribution of the actives and to improve particle sizedistribution and shape yielding stronger and more consistenttablets.ENHANCING DISSOLUTIONExample curry powder: Due to high fat content, curry powdersare difficult to dissolve. Through fluid bed granulation,these powders are converted to flowable, lump-free granuleswith enhanced water dissolution properties.TRANSFORMATION OF LIQUIDS TO GRANULESExample malt extract: Through spray granulation, concentratedextracts are converted to dry, flowable granules thusimproving handling and shelf life compared with the liquidextract.5

ProcessesFLUID BED DRYINGFluid bed dryers make the thermal treatment of bulksolids particularly effective. The efficient heat and masstransfer of a fluid bed creates optimal conditions forfast, efficient drying and cooling.FLUID BED GRANULATION(AGGLOMERATION)During a fluid bed granulation, a powder is fluidized withair. In this condition, individual particles are easy accessible.Using spray nozzles, the fluidized powder is sprayed witha liquid (water, binder solution, etc.). Due to the surfacemoisture, and sometimes the presence of a binder, the particlesstick together forming granules (agglomerates). Theagglomerated product is easier to dissolve and segregationof single recipe components can be avoided. As spraysolution besides water also vitamins, fat or lecithin can beused, gaining an added value. Through fluid bed granulation,critical characteristics of the particle or the product can beexactly defined: porosity, particle size distribution, bulk density,dust content, dissolution.FLUID BED GRANULATION (AGGLOMERATION)Binder dropsPowderFinal agglomeratesSpraying Wetting Drying6

ProcessesCOATINGThrough the process of fluid bed coating, fluidized particlesare continuously sprayed with a coating solution, depositinglayers (films) of material to the surface of the particles, andyielding an even layer with a particular thickness. Coating ofparticles can serve many purposes, depending on the product:Visual appearance, taste masking, controlled release,light/oxygen/humidity protection, are a few examples.coatingCoating slurry(e.g. suspension, solution,emulsion, melt, fat)Active agent or coating kernelSpraying Wetting Drying LayeringMICROENCAPSULATIONThrough the process of microencapsulation, solid or liquidactive ingredients are homogeneously embedded into a carriermaterial, producing a stable product with defined characteristics.This process is especially useful for controlled andtargeted release of Active Pharmaceutical Ingredients (API’s),food additives, flavors, etc.MICROENCAPSULATIONSlurry with active ingredientsStart kernelFinal granuleSpraying Wetting Drying Encapsulation8

Process surveyProcess Primary Products End Products Product Benefits Product ExamplesDRYINGWet Product(e.g. granules, powders,pellets, filter cakes)Dry Product· Shelf Life· Product stability· Short drying time· Controlled, gentle andhomogeneous drying· Drying at defined temperatures/profiles· Preservation of functionalproperties like vitamin content· Plastic granules· Pharmaceutical granules· Starch· Caffeine extrudate· PTFE powder· Lecithin· Vitamins· Silica gel· Pollen granules· Cellulose· Aluminum oxideGRANULATION(AGGLOMERATION)Fine Powder orPowder Blending+ Binder(e.g. water,suspensions)Agglomerates· Good instant properties· Good dissolution· Dust-free product· Good flowability· Minimum segregation· Narrow particle size distribution· Defined bulk density· Porous particle structure· Good dispersibility· Tabletting characteristics· Instant drink powders· Soups and sauces· Baby food· Cacao drinks· Cappuccino· Starch· Milk powder· Cellulose· Sugar substitutes· Lactose· Pharmaceutical productsSPRAY GRANULATIONStart Granules(seeds from original orsecondary material)+ Suspensions,Emulsions,Solutions orMeltsGranules· Nearly round particles· Dust-free product· Good flowability· Good to dosage· Narrow particle size distribution· High bulk density· Compact particle structure· Minimum friability· Building of solid particles fromliquid products· Aromas· Calcium lactate· Aluminum oxide· Starch· Sodium silicate· Zirconium oxide· Urea· Ammonium sulfate· Detergents· Menthol granules· Calcium carbonateMICRO-ENCAPSULATIONStart Granules(seeds from original orsecondary material)+ Suspensions,Emulsions orSolutions withActive AgentsMicroencapsulatedGranules· Shelf life· Encapsulation of volatilecomponents· Protection against chemical reactions· Protection against oxygen or light· Protection against humidity· Depot effect· Narrow particle size distribution· High bulk density· Building of solid particles fromliquid products· Scent oils· Aromas· Perfumes· Vitamins· Lactic acid bacillus· Enzymes· Starter cultures· Omega-3 fatty acids, fish oils· Pigments· Amino acids· MineralsSPRAY DRYINGAGGLOMERATIONStart Granules(seeds from original orsecondary material)+ Suspensions,Emulsions,Solutions orMeltsAgglomerates· Good instant properties· Good dissolution· Dust-free product· Good flowability· Defined particle size distribution· Defined bulk density· Good dispersibility· Production of innovative newproducts through combining anysolid and liquid substance· Malt drink· Plant protectants· Ginseng· Aromas· Vitamins· Plant extracts· Spore ferments· Instant coffee· Proteins· Beverage powders· EnzymesCOATINGGranules, Pellets,Extrudates, Powders orTablets+ Coating Material(e.g. suspensions,polymers or fats)Coated Product· Shelf Life· Defined dissolution· Optical effects (color, gloss)· Reducing of hygroscopicity· Protective functions· Taste masking· Odor masking· Functional properties· Defined surface structure· Depot effect· Enteric-coated· Tablets· Cereals· Sugar· Dietary supplements· Seeds· Aspartame· Lemon acid· Ascorbic acid· Pharmaceutical products· Enzymes· Aromas

TechnologyFROM THE SINGLE MACHINE TO THE COMPLETE SYSTEMThe fluid bed machine is the heart of the system, and is entirelysupplied by NEUHAUS NEOTEC, including complete airhandling, product feeding, product discharge, and controls.In addition, NEUHAUS NEOTEC can also be the general contractorfor the design of complete production lines.• Totally closed plants, no open product handling• Supply / exhaust air conditioning• Heat recovery systems• Automation solutionsFURTHER OPTIONAL COMPONENTS:• Supply systems for the primary compounds• Conveyors• Silos• Mechanical granulation systems• Grinding of primary substances and final products• Size classification (sieving), re-feeding systems• Product packagingCONTINUOUS OR BATCH?The modular design and expandable configurations of oursystems ensure the sustainability of your investment forfuture expansions. We offer batch and continuous systems:For batch processing of defined product quantities our BatchFB fluid bed systems are ideal. For the efficient, low-costmass production our continuous systems Conti FB are mostappropriate.Bottom-Spray nozzleDistributor plates and nozzle configurationare individually adapted to yourapplications10

Conti FBCONTI FB - CONTINUOUS FLUID BED SYSTEMThe basic concept of the Conti FB is based on a design that incorporatesseveral inlet and exhaust air compartments, eachof which is equipped with its own supply air system (heatingor cooling). Process parameters for each zone (temperatureand flow) can therefore be adjusted to provide maximumcontrol of the process and product characteristics.Exhaust Air HoodIntegrated filter cartridges and product weirsenable a secure and multi functional use ofthe plantsThis fully automated system is operated with minimalinvolvement, and can be programmed to handle multiplerecipes with varying process parameters. The Conti FB canbe used as continuous dryer, granulator (agglomerator), orcontinuous spray granulator producing high quality, consistentproducts.• Multi-stage operation• Top- or bottom-spray• Internal or external filtration system• Vibrating or static systems• Nozzles in every section, height adjustable, removable• Product weirs for sectioning• Through-the-wall-installation: separation of technical/production areaExemplary Functional ChartContinuous fluid bed plant with 5 sections andtop- resp. bottom-spray equipment12

Extensible NozzlesThe spray lances can be removed evenduring operation and placed at differentheight positionsPharmaceutical DesignNEUHAUS NEOTEC projects all plants on basisof individual clients demandsAccessibilityEasy cleaning and maintenance dueto easy access to the processing partsExecutionDepending on process and product,the machine is designed as a staticor vibrating fluid bed13

Batch FBBATCH FB – BATCH FLUID BED SYSTEMSBatch FB systems are generally used for processing smallerquantities of multiple products. Whenever fast cycle timesplay no important role and either defined batch sizes shouldbe processed or a frequently change of products is planned,batch systems are appropriate. As well, batch systems aremore suited for products requiring multiple, complex steps.In contrast to continuous processing, batch processing stepsare sequential.Batch systems are less complex than continuous systems.Anyhow the clue for a most efficient and flexible batch plantdesign is the entire engineering, from process technology toselection of the appropriate components.Beside the Batch FB, NEUHAUS NEOTEC provides the necessaryauxiliary components that make up the rest of thesystem: spray tank, binder conditioning, cleaning stations,grinding equipment, lifting column and others. The entire infrastructurecan be integrated into the overall system control.• Pressure shock rating up to 12 bar• Single chamber-, double chamber shaking- orcartridge-filter systems• Top- or bottom-spray• Wurster insert• Various product supply and discharge methodsExemplary Functional ChartBatch fluid bed plant with top- resp.bottom-spray device14

Automated OperationThe recipe ingredients can be composedautomatically and pneumatically fedinto the apparatusFilterThe selection of the appropriate filter systemdepends on the individual demands plusproduct- and process-criteriaMaterial ContainerLarge production plants are assembledwith a hinged material container system15

LaboratoryLABORATORY AND PILOTSCALE SYSTEMSWe offer high-performance laboratory and pilot plant systemsfor continuous and batch processing in different designs.Our laboratory systems allow you to optimize yourformulations, process parameters, and product characteristicsprior large scale production. This equipment can be usedto conduct feasibility studies, develop new and innovativeproducts on a small scale. It can be a great asset to R&D departmentsfor developing new products, as well as supportingproduction systems.Conti FB PilotProcess optimization and scale-upOUR LABORATORY AND PILOT PLANTS:Conti FB Pilot for all continuous fluid bedprocesses from 5 to 50 kg/hmobatchMobile plant for laboratory applicationsand small product quantitiesmobatch, a flexible mobile batch plant forproduct amounts up to 8 kgminibatch, a mobile batch plant for productamounts from 50 to 2.000 gHIGHLY SPECIALIZED TECHNICAL CENTERIn our state-of-the-art Technical Center, we offer you the optionto test your products, and processes. We start on thelaboratory scale level (batch systems) to prove feasibility andoptimize process parameters then we scale-up to continuousor batch production plant sizes.Technical CenterIn our pilot plant facility, productscan be tested and process parametersoptimizedDetailed SolutionsInlet air distributor sections (left),stainless steel cartridge filter (right)16

Made in GermanyENGINEERING AND PLANTS MADE IN GERMANYNEUHAUS NEOTEC is specialized in manufacturing of process engineering plants for the food industry, the fine chemicals, thechemical and the pharmaceutical industry as well as for the biotechnology. In plant constructing for the coffee industry, weare one of the leading companies worldwide. Our fluid bed systems are based on the technologies of HEINEN DRYING® andthey are determined by a maximum of flexibility in construction and functionality of the plants. We take care of all concernsfrom process development to realization of single machines and overall solutions including the complete peripheral devices:With you, we are planning and developing your individual process solution.NEUHAUS NEOTEC GmbHHeadquarter in GanderkeseeHighly modern equipment and extraordinaryprocess competence17

Changes in design reserved. NN 01 06.12 GBNEUHAUS NEOTEC (Ganderkesee) Maschinen- und Anlagenbau GmbH Fockestraße 67 • D - 27777 Ganderkesee • Fon: +49 (0)4221-859-0 • Fax: +49 (0)4221-859-520NEUHAUS NEOTEC (Reinbek) Maschinen- und Anlagenbau GmbH Dieselstraße 5-9 • D - 21465 Reinbek • Fon: +49 (0)40-72771-500 • Fax: +49 (0)40-72771-550nnsales@neuhaus-neotec.de • www.neuhaus-neotec.de